Gen 5 Core (EVA + EPP) Thermoformed Pickleball Paddle Manufacturer: Boomstick OEM Guide

When I talk with our customers about “premium paddles,” I keep seeing the same misunderstanding: people think premium = a fancier material name.

But in real OEM projects, what decides whether a Gen 5 line actually sells (and whether you get complaints later) is much more practical:

The foam density level (expansion ratio)
How stable the process is in mass production
Whether the face design + texture method match the “premium” positioning

Boomstick Core is basically what many buyers call Gen 5: EVA + EPP foam core. When tuned correctly, it gives an “immediate difference” feel: more alive, more rebound, more forward push, and a steadier sweet spot.

And one market note from real conversations: Vietnam buyers often care a lot about elasticity and rebound. That’s why we developed a Vietnam-tuned high-elasticity version and the feedback has been very positive, because the difference is obvious on the first few hits.

Who this guide is for

This guide is for you if:

You want a premium / flagship paddle line that feels different immediately
You sell into Vietnam / Southeast Asia where “high elasticity” is a strong preference
You already have entry models and want a clear upgrade path without batch-risk
You want to avoid the classic nightmare: samples feel great, mass production feels different

Boomstick Core (EVA + EPP) in one simple explanation

Boomstick / Gen 5 (EVA + EPP) is a controlled foam system that lets you build a premium feel around:

More rebound and “alive” response
A more stable sweet spot
Better comfort when the structure is tuned correctly

But here’s the truth: the name doesn’t guarantee the result. Density (foam level) + process stability decide whether it’s “real premium” or just a label.

Why density level is the first decision you must get right

Many articles say “Gen 5 is hot,” but as a buyer you still need a real decision: which density level are you choosing?
Two paddles can both be called EVA + EPP, but feel completely different if the density level is different.

One more thing I’ll say clearly: we only produce high-density foam core systems (8x–10x expansion).
Lower-density options might look cheaper, but they usually create more risk in lifespan and batch consistency. We’d rather keep the core stable than chase a low price that can damage your brand later.

How the manufacturing reality works (no “mystery talk”)

From an OEM perspective, Gen 5 success comes down to one word: consistency.

If a factory can’t control the process, you’ll see problems like:

Samples feel bouncy, but mass production turns softer
Different batches feel different
Thickness / weight drift causes “this one feels different” complaints

A factory that can truly run Gen 5 well should be able to define and control:

Foam density level (expansion ratio) clearly
Stable forming parameters (so feel doesn’t drift)
Thickness tolerance control
Weight range control (and ideally swing weight range targets)
Texture durability (so “spin feel” doesn’t wear unevenly)

How to choose the density level

Before you read the table, remember this line: we only recommend and mass-produce stable premium pickleball paddle in 8x–10x.
Premium isn’t “softer.” Premium is “rebound stays stable, batch stays stable.”

Expansion ratio / density range	Practical rating	Feel tendency	Best positioning	What I would NOT do
8x (110–115)	Best (highest density, most stable)	Strong rebound, very solid load-bearing	Flagship / top premium	Don’t use it for low-price wars
9x (100–105)	Best (premium mainstream)	Great balance of rebound + stability	Main premium seller / profit model	Don’t market it as “soft”
10x (85–95)	Excellent (high-elastic upgrade)	Easier to feel “bounce”	Premium entry / profit upgrade	Don’t oversell it as “ultimate flagship”
11x (75–80)	Soft	Can feel “flat” if not tuned	Special control projects	Don’t build your core line on it
13x (60–70)	Soft	More energy loss	Special requests	Don’t position as premium
15x (50–55)	Soft	Stability risk rises	Rare cases	Don’t use for premium claims
17x (40–45)	Too soft	“Mushy” / low rebound stability	Non-mainstream	Not recommended

Simple rule: smaller expansion ratio = higher density = stronger load-bearing = more stable rebound (and higher cost).

Recommended shapes and sizes (a direct “menu” you can pick from)

To make selection faster, here are the common choices we run for Gen 5 / Boomstick core pickleball paddle:

Flat shape / Hybrid shape

417 × 190 × 13mm
417 × 190 × 14mm
417 × 190 × 16mm

Widebody shape

400 × 200 × 16mm
400 × 200 × 14mm

If you want a more “all-around” advanced feel, 417 × 190 is a very common premium direction

If you want an easier-to-sell premium feel for broader players, widebody is often a safer start.

Face design + texture method (how to make it look and feel premium)

For premium pickleball paddles, I strongly recommend matching the design style to the texture method.

Why premium pickleball paddles should lean “clean design + cloth-matte texture”

Premium often looks more premium pickleball paddles when the material feel is visible, not fully covered by heavy graphics
Cloth-matte texture pairs well with minimal, clean designs
We can also build a “roughness-forward” feel that is more durable, so the premium texture doesn’t fade quickly
It helps reduce long-term complaints like “the sample feels great, but texture wears unevenly”

Sound and feel: is Gen 5 core “crisp” or “deep”?

Gen 5 core (EVA + EPP) usually feels more “alive” and responsive.
Sound-wise, it’s typically:

Not as deep and “thumpy” as pure EPP
Not as crisp and “poppy” as Gen 4-style (PP-based) cores

It sits in the middle, and many advanced players love that balance because it gives forward push without an overly hard/crisp feel.

Lifespan and batch consistency (why premium needs tighter control)

The biggest loss for a brand is not “it didn’t sell.”
It’s “it sold, then complaints started because batches feel different.”

For Gen 5 projects, the brand-critical controls are:

Clear thickness target (13 / 14 / 16, not vague)
Weight range targets (premium needs tighter control)
Consistent rebound feel across batches
Texture durability stability (so “spin feel” doesn’t fade unevenly)

Pitfalls buyers should avoid (I’ll write this one a bit “hard”)

Asking “Is it Gen 5?” but not asking the density level
Samples tuned bouncy, mass production becomes softer
Chasing “more bounce” without stability planning (leads to lifespan risk)
Paying for a premium name while the factory can’t define the structure clearly
Using heavy color designs that cover premium face material texture
Not defining premium specs clearly (if you don’t define it, the factory will choose the easiest path)

A practical note

Premium pickleball paddles is not just raising the price. Premium means your pickleball paddle stays consistent after you scale.

If you want to build a Gen 5 Boomstick core line that actually holds up, I suggest you lock these three things early:

Density level (8x–10x)
Shape + size (from the menu above)
Texture method matched to premium design (clean + cloth-matte is usually the safest premium route)

That’s how a premium paddle becomes a premium product line, not a one-batch experiment.

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Zoey Tse

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