A breakthrough technology has allowed us to design and manufacture a longboard with a unique shape that gives rider's versatility never before seen on a board. The Hanzo is a dropthrough longboard that is very low to the ground. This allows for easy pushing for long distances. The unique Wingtail design brings back a kicktail that was previously not possible in dropthrough boards. Aerospace technology that bonds the wood veneers makes it possible to lay up a board without any glues or epoxy making it both extremely durable and 100% recyclable.

We set out to solve two major problems:

1. Dropthrough longboards that are great as alternative transportation because they are low to the ground. But in order to make it low, they have to have cutouts to make room for the wheels so they don't hit the board when you turn (wheelbite), but this effectively eliminates the kicktail. It narrows the use for the board, leaving it good for distance and freeriding, but limits its use versatility and fun that the kicktail originally provided. We set out to bring back the kicktail while retaining all the benefits of a low profile long distance ride that a dropthrough board provides.

2. Traditional board manufacturing consists of using wood, epoxies, glues, and fiberglass. Production methods are toxic for both the workers at the factory and for the environment. Our challenge was to employ a manufacturing process that is safe for productions workers and 100% recyclable. We overcame this challenge by using cutting edge thermo binding technology. Sheets of wood are sandwiched with thermo-composite layers, creating a life long lasting bond that is weather resistant. Factory workers don't even need to wear dust masks. A bonus to this method is also the speed we are able to produce the boards. Because no glues are used that need to cure we can produce boards at rates of under 10 minutes from start to finish compared to several hours with traditional methods.

Initially the goal was to figure out a way to bend the wood in the extreme way necessary to keep the dropthrough functionality of the longboard while bringing back the kicktail. The focus of the design is to have a board that is not only comfortable for commutes, but is also able to perform traditional tricks of shortboards. Further design development was made on the concave and shape of the board to be able to "cup" your feet into place at key locations necessary to slide the board as a snowboard would slide (stand up slides). But as I learned how toxic and non recyclable composite skateboards are it became clear that I needed to not only have the desired form, but to also rethink the manufacturing process so we could have a socially conscious product. It took 3 years to find the right shape and process that allows for the radical bends of the maple veneers.

Wood does not like to bend in two different directions. I knew we needed extreme pressure and heat to achieve the bends in the design. But the amount needed didn't exist in traditional board construction. Therefore, I developed a system of precutting the veneers at various points to allow the wood to bend in the desired form using standard presses. After a few prototypes, I saw success in the shape but the manufacturing time and toxicity of the layup was not appealing. Further materials research lead to the discovery of an aerospace manufacturer that employs a no glue or epoxy system making it 100% recyclable. Workers don't even need to wear breathing masks. Not only was it great that I found an environmentally friendly manufacturing process, it turned out to be an amazingly fortuitous coincidence that this new manufacturing technique uses the exact heat and pressure requirements we also need to bend the wood in the extreme manner we are doing in our design.

It has become clear that with population growth we desperately need alternative forms of transportation that are socially and environmentally conscious. Longboards provide a great form of alternative transportation. And unlike bicycles are extremely easy to take on to subways and busses to complete the "final mile" of your destination. The Hanzo wingtail design brings together the best in various board designs into one. It brings together the comfort of dropthrough designs with the agility and fun of boards with full kicktails.