Abstract: A method of forming a fin configured for use with a water sports board. The method includes providing a mold having a mold cavity and a first insert pre-preg sheet each including structural strands bonded by a first resin material. The method further includes placing the first insert pre-preg sheet within the mold cavity. The method further includes injecting a third resin material under pressure into the mold cavity. The method further includes injecting a core substance only in the form of a gaseous material into the third resin material to form a unitary hollow volume within the third resin material.

Abstract: A method of forming a fin configured for use with a water sports board. The method includes providing a mold having a mold cavity and first and second insert pre-preg sheets each including structural strands respectively bonded by first and second resin materials. The method further includes placing the insert pre-preg sheets within the mold cavity. The method further includes injecting a third resin material under pressure into the mold cavity between the first insert pre-preg sheet and the second insert pre-preg sheet to urge the first insert pre-preg sheet and the second insert pre-preg sheet away from each other and towards respective ones of the pair of mold cavity faces, and dispose the third resin material between the first insert pre-preg sheet and the second insert pre-preg sheet to space at least a portion of the first insert pre-preg sheet from the second insert pre-preg sheet.

Abstract: An insert for a water sports board, wherein the insert includes a pre-preg flange extending outwardly from an injection molded central housing to provide enhance structural properties of the insert, as well as enhanced intermediate bonding between the injection molded central housing and a surface polymer. The pre-preg flange further improves the strength to weight ratio when compared to conventional inserts.

Abstract: A structure, such as a fin or water sports board, including a core having opposed first and second core outer surfaces. The structure further includes first and second fiber sheets, wherein the first fiber sheet extends along the first core outer surface and the second fiber sheet extends along the second core outer surface. A thermoplastic material impregnates the first fiber sheet and the second fiber sheet and bonds the first fiber sheet and the second fiber sheet to the core. The thermoplastic material defines an outer surface of the structure.

Abstract: A method of forming a fin configured for use with a water sports board. The method includes providing a mold having a mold cavity and first and second insert pre-preg sheets each including structural strands respectively bonded by first and second resin materials. The method further includes placing the insert pre-preg sheets within the mold cavity. The method further includes injecting a third resin material under pressure into the mold cavity between the first insert pre-preg sheet and the second insert pre-preg sheet to urge the first insert pre-preg sheet and the second insert pre-preg sheet away from each other and towards respective ones of the pair of mold cavity faces, and dispose the third resin material between the first insert pre-preg sheet and the second insert pre-preg sheet to space at least a portion of the first insert pre-preg sheet from the second insert pre-preg sheet.

Abstract: A fin for a water sports board including leading and trailing edges, and a base extending therebetween along a longitudinal base axis. A fin axis extends generally perpendicular to the longitudinal base axis, both axes residing within a longitudinal plane. First and second opposed side faces are formed on generally opposed sides of the longitudinal plane. First and second insert pre-preg sheets formed of structural strands bonded by a resin material are disposed adjacent respective ones of the first and second side faces on generally opposed sides of the longitudinal plane. An injection molded resin material is disposed between the first and second insert pre-preg sheets. A core is positioned between the first and second insert pre-preg sheets and is of a density less than the injection molded resin material.

Abstract: A structure, such as a fin or water sports board, including a core having opposed first and second core outer surfaces. The structure further includes first and second fiber sheets, wherein the first fiber sheet extends along the first core outer surface and the second fiber sheet extends along the second core outer surface. A thermoplastic material impregnates the first fiber sheet and the second fiber sheet and bonds the first fiber sheet and the second fiber sheet to the core. The thermoplastic material defines an outer surface of the structure.

Abstract: An insert for a water sports board, wherein the insert includes a pre-preg flange extending outwardly from an injection molded central housing to provide enhance structural properties of the insert, as well as enhanced intermediate bonding between the injection molded central housing and a surface polymer. The pre-preg flange further improves the strength to weight ratio when compared to conventional inserts.

Abstract: A fin for a water sports board including leading and trailing edges, and a base extending therebetween along a longitudinal base axis. A fin axis extends generally perpendicular to the longitudinal base axis, both axes residing within a longitudinal plane. First and second opposed side faces are formed on generally opposed sides of the longitudinal plane. First and second insert pre-preg sheets formed of structural strands bonded by a resin material are disposed adjacent respective ones of the first and second side faces on generally opposed sides of the longitudinal plane. An injection molded resin material is disposed between the first and second insert pre-preg sheets. A core is positioned between the first and second insert pre-preg sheets and is of a density less than the injection molded resin material.