The paddle face typically utilizes carbon fiber or fiberglass fabric; these materials are cut and layered according to specific orientations (such as alternating 0°, 45°, and 90° angles) to optimize tensile and torsional strength across different directions. Meanwhile, the internal honeycomb core (e.g., polymer honeycomb) is pre-cut to meet thickness and density specifications, ensuring structural uniformity.

Lamination and molding constitute the most critical step. Once the carbon fiber layers and honeycomb core are assembled, the unit undergoes heat or cold pressing within a mold. During heat pressing, the resin cures under high temperature and pressure, tightly bonding the carbon fiber to the core to create an integrated structure; this method yields superior strength and stability and is the standard process for mid-to-high-end paddles.

After molding, the paddle undergoes precision cutting to remove excess edge material, followed by the installation of an edge guard. Some models also incorporate vibration-dampening materials within the frame to minimize vibration transmission upon impact and enhance comfort. This stage significantly influences the finished product's durability and user experience.

The paddle face undergoes sandblasting, matte finishing, or specialized coating to increase friction and wear resistance, thereby improving spin control. Finally, the paddle is subjected to rigorous testing-covering weight, balance point, rigidity, and impact performance-to ensure every unit meets design specifications.