Thermoformed vs. Cold Pressed: Which Manufacturing Process Fits Your Brand?

In the world of high-performance pickleball, the “Engine” of the paddle matters just as much as the “Tires” (the surface material).

For B2B buyers and product managers, choosing between Thermoforming (often called Gen 3) and traditional Cold Pressing is the most critical decision you will make for your 2025 product lineup. As a premier Thermoformed pickleball paddle manufacturer, Joying Pickleball is here to break down the technical differences.

1. Cold Pressed Paddles: The Traditional Reliable Choice

This process involves creating the core (honeycomb) and the face sheets separately, then bonding them together using adhesive under pressure—without high heat.

• Pros:
  • Cost-Effective: Lower production costs mean better margins for entry-level to mid-range products.
  • Design Flexibility: Easier to apply complex graphic prints.
  • Soft Feel: Many control-oriented players prefer the softer feedback of a cold-pressed paddle.
• Cons:
  • Durability: Over time, the glue can degrade, leading to “dead spots” or delamination.

2. Thermoformed (Gen 3) Paddles: The New Standard

If your target audience is 4.0+ rated players, they are likely searching for “Gen 3” or Unibody paddles.

Thermoforming uses intense heat and pressure to fuse the carbon fiber face directly into the core material, often sealing the edges with foam.

• The “Unibody” Advantage: The handle and the paddle face are forged as one solid piece. No weak points at the neck.
• Pros:
  • Explosive Power: The stiffer structure transfers more energy to the ball.
  • Edge-to-Edge Sweet Spot: Foam-injected walls (perimeter weighting) expand the hitting area.
  • Extreme Durability: Virtually impossible to delaminate.
• Cons:
  • Higher Cost: Requires expensive molds and longer production time.

3. Which Should You Manufacture?

Here is our recommendation based on your target market:

Conclusion: We Manufacture Both

At Joying Pickleball, we don’t force you into one technology. We have production lines for both cost-effective cold-pressed paddles and cutting-edge USAPA approved thermoformed paddles.

Whether you want to dominate the budget market or challenge the top pro brands, we have the molds and the expertise.