Board Stories: Engineering Art for Insightec

When Katie Davis approached us to create a set of custom surfboards for Insightec, we knew this design was going to be the challenge of the year, but we were stoked to dive into it. Insightec is a company built on precision technology, and they needed a physical piece of art for their tradeshows that reflected that same level of innovation and detail.

The Vision: A Complex Intersecting Sea

The design concept was ambitious: a series of tiny, tight waves intersecting across the board’s surface. To make it even more complex, Insightec wanted specific waves to be filled with different colors of epoxy.

In the world of hollow wood board building, “intersecting waves” means every single piece of wood must be perfectly calculated. If the lines are off by even a fraction of a millimeter, the structural integrity of the “skeleton” is compromised, and the aesthetic flow is lost.

From Sketch to Laser: The Technical Hurdle

Our process always begins with the customer’s vision, but for Insightec, the translation from a sketch to a finished board required deep technical problem-solving.

1. Digital Transposition: We took the original design sketch and transposed it into a precision laser-cutting file.

2. The “Epoxy Barrier” Problem: The most significant challenge was adjusting the lines of the waves to ensure the wood pieces acted as a perfect dam. We had to ensure that the wood cutouts intersected in a way that kept the different colored epoxies completely separated.

3. Preventing the Bleed: Because the waves were so small and close together, we had to be meticulous. If the wood didn’t fit perfectly, the two colors of epoxy would cross or mix, ruining the crisp, high-tech look the client required.

Challenging, But Worth the Journey

This project pushed our “Artisan Craft” value to its limit. It wasn’t just about building a board; it was about engineering a puzzle where wood and liquid resin meet with surgical precision.

While it was easily one of our most challenging builds to date, seeing these boards ready for the tradeshow floor was incredibly rewarding. They stand as a testament to what happens when Northern Michigan craftsmanship meets high-tech inspiration.

Do you have a complex design vision for a custom board? Whether it’s for a corporate display or your private collection, we love a good challenge. [Inquire about a Custom Build]

Sketches are done, ready for wood selection….

Clarky carefully assembling the tiny pieces of the wave design on the skin, built from Red Cedar and Colorado Aspen woods. View/Share on Instagram

What a gorgeous board to be very proud of. Thanks to Resin Research and Black Diamond Pigments for the best product to make this happen.