ZEAL sticks and shafts are genuine one-piece construction made in small batches and finished by hand in Providence, Rhode Island.
We use the finest military-grade, ultra lightweight carbon fiber. Our laminate structure consists of 9 layers of unidirectional carbon prepreg fiber. The raw materials are stored at 40 degrees. Each layer is precisely cut with a CNC cutter. Specific angles and lengths determine the shafts point of flexion (or "kickpoint") and stiffness (or "flex").
Each layer is hand-rolled around a cylindrical rod (or "mandrel") to form the shape of the stick. The blade is then formed by hand with a compressible urethane insert. Layers of laminate are then fused to join blade and shaft. Next these laminate layers are inserted into our single cavity mono compression molds.
Several thousand carbon fibers undergo a treatment process that forges a composite having a very high strength-to-weight ratio. Fibers are bundled together to form spools of continuous threadlike filaments known as tows, which are woven into long sheets of fabric.
Carbon fibers have several advantages including high stiffness, high strength, low weight, high chemical resistance, high temperature tolerance and low thermal expansion. These properties have made carbon fiber very popular in aerospace, civil engineering, military, and motorsports, along with other competition sports.