Section 1: What Is a Gen 5 Pickleball Paddle?
In today’s high-performance pickleball market, the term “Gen 5 pickleball paddle” doesn’t just refer to a new version—it represents a major leap in paddle core technology. Gen 5 paddles are engineered around a hybrid EVA + EPP core system, delivering a unique combination of power, control, and durability that surpasses previous generations.
At the core of this innovation is the fusion of two advanced materials. EVA foam offers high elasticity and rebound, giving players a lively, responsive feel during fast-paced exchanges. EPP, on the other hand, is an aerospace-grade foam that provides structural support and stability. Together, they form a dual-core platform that’s more stable, more consistent, and more versatile than traditional polypropylene honeycomb or single-foam paddles.
Gen 5 paddles also pair seamlessly with thermoformed T700 carbon fiber surfaces, allowing brands to fine-tune dwell time, vibration feedback, and overall paddle response. The result? A larger sweet spot, optimized control on soft shots, and explosive power on drives—all in one design.
For brands looking to stand out in a competitive market, the Gen 5 pickleball paddle offers more than just next-level play—it tells a story of engineering, innovation, and elite performance.
Section 2: Performance Advantages of Gen 5 Paddle Core
Larger Sweet Spot, Better Control
One of the first things players notice with a Gen 5 pickleball paddle is the expanded sweet spot. Thanks to the structural support from the EPP layer, the hitting zone feels more stable and forgiving. Whether you’re resetting at the kitchen or countering a drive, the paddle gives U more control with less effort—especially valuable during fast-paced exchanges.
Durability That Holds Under Pressure
Unlike traditional EVA cores that may compress or deform over time, the Gen 5 hybrid structure resists fatigue. The aerospace-grade EPP is not only 30% lighter than conventional foams, but also twice as hard as standard EVA. Combined, they form a core that maintains shape and consistency—even after months of aggressive play. It’s built for long-term performance, not just first impressions.
Balanced Power and Touch
The EVA component brings elastic rebound, giving shots the pop and energy advanced players demand. But because it’s paired with a rigid EPP support layer, the result is controlled energy—not a wild trampoline effect. Players get powerful drives when needed, without losing feel on soft shots like dinks or blocks.
Tuned Sound and Feedback
Sound matters more than most people think. Gen 5 paddles strike a perfect middle ground—more crisp than EPP-only paddles, but without the overly sharp ping of polypropylene. This tuned acoustic feedback, combined with a stable vibration profile, gives players better confidence and hand feel.
Gen 5 paddles aren’t just about better specs—they’re about better play. For paddle brands aiming to lead in performance and innovation, this is the upgrade serious players are already searching for.
Section 3: EPP Material – Aerospace-Grade Performance in Your Paddle
What Is EPP and Why It Matters
Expanded Polypropylene (EPP) is a high-performance foam originally used in aerospace and automotive industries for its excellent impact resistance and structural strength. Now, it’s reshaping the future of pickleball paddle design. In Gen 5 paddles, EPP acts as the structural backbone—helping create a paddle that’s not only lighter but also more durable and stable over time.
Compared to traditional foam cores, EPP is about 30% lighter and twice as hard as standard EVA. This means the paddle stays consistent even after heavy use, with less risk of core breakdown or deformation. For competitive players, that translates into longer-lasting performance and a more reliable feel during every match.
Why Combine EPP with EVA?
The real breakthrough of Gen 5 paddle design lies in the combination of EPP and EVA foams. EVA adds elasticity and rebound—giving players that lively “pop” during drives and fast counters. EPP provides structural support, keeping the paddle firm, balanced, and stable on impact.
This hybrid structure allows for a larger, more forgiving sweet spot and better shot control across the entire face of the paddle. Whether you’re resetting at the net or driving from the baseline, the paddle adapts to your style while maintaining its shape and responsiveness.
Engineered for Precision Performance
EPP also offers excellent tunability. Manufacturers can adjust its expansion ratio, thickness, and positioning to fine-tune the paddle’s feel, control, and power. For example, with expansion ratios around 8x–10x, paddles can be designed to match different player needs—from soft-touch finesse paddles to hard-hitting power models.
In short, EPP isn’t just a lightweight material—it’s a core component of high-performance design. When used correctly in a Gen 5 pickleball paddle, it helps deliver better control, longer lifespan, and a more consistent playing experience. For brands ready to offer something beyond the ordinary, aerospace-grade EPP is the material that takes paddle performance to the next level.
Section 4: Why High-End Paddle Lines Are Using Gen 5 Pickleball Paddles
Perfect for Flagship Models
Many paddle brands are now choosing Gen 5 pickleball paddles for their top-tier product lines. The hybrid EVA + EPP core delivers a better feel, more control, and excellent durability—exactly what experienced players look for in a premium paddle.
When combined with raw carbon fiber surfaces, Gen 5 paddles offer a clear upgrade in both performance and design. This gives brands a strong story to support higher retail pricing and create standout models in competitive markets.
Made for Serious Players
Gen 5 paddles are built for 3.5+ level players who want both power and control. The large sweet spot, stable core, and consistent feedback give a high-end playing experience that casual models can’t match. That’s why more brands are using Gen 5 construction in their pro-level or signature series paddles.
Tunable to Your Market
Another key advantage is flexibility. Core density, thickness, and feel can be adjusted to match different play styles—control-focused, power-driven, or balanced. With one Gen 5 platform, brands can develop multiple models for different customer groups.
For any brand aiming to lead with quality and performance, Gen 5 pickleball paddles are the foundation of a next-generation product line.
Section 5: Gen 5 Paddle Case Study – Selkirk Labs Project Boomstik
A Real-World Example of Gen 5 Done Right
One of the most well-known examples of a Gen 5 pickleball paddle in the market is the Selkirk Labs Project Boomstik. This paddle showcases exactly how high-end brands are using EVA + EPP hybrid cores to push the limits of paddle performance.
By pairing a thermoformed T700 raw carbon fiber face with a carefully tuned EVA + EPP core, the Boomstik delivers explosive power, a massive sweet spot, and solid control—all in one frame. It’s designed specifically for aggressive players who still need reliable touch at the net. The result is a paddle that feels alive in your hand, yet stable on contact.
Why It Works
Selkirk’s approach shows the strength of Gen 5 design: combining materials that work together, not just adding features. The foam density is tuned to deliver both dwell time and rebound, while the paddle face enhances spin and pop. It’s also a paddle that justifies its higher price through real, noticeable performance—not gimmicks.
What Brands Can Learn
Project Boomstik proves that Gen 5 paddles are not just a trend—they’re a new category. If your brand is planning to launch a flagship or pro-level paddle, Gen 5 construction offers the technology and feel that top-tier players expect. With the right design and messaging, it can also help you establish a stronger position in the premium paddle market.
At PKZK, we help brands apply these same principles to create their own custom Gen 5 paddles—tailored to your identity, performance goals, and target audience.
Section 6: Why Work With PKZK for Gen 5 Paddle OEM
Thermoforming Expertise for Gen 5 Paddle Production
PKZK Pickleball specializes in high-performance paddle manufacturing, with full thermoforming capability for Gen 5 pickleball paddles. We use premium T700 carbon fiber, aerospace-grade EPP foam, and high-elasticity EVA to build paddles that meet pro-level expectations.
Our integrated process includes high-pressure thermoforming, raw material shaping, precision bonding, and full paddle assembly. This ensures each paddle delivers consistent quality—both in feel and long-term durability.
Custom Shapes, Core Designs, and Surface Materials
Whether you’re developing a new model or upgrading an existing one, we offer complete customization options:
- Épaisseur du noyau: Available in 13mm, 14mm, 16mm, and 19mm
- Foam Density Tuning: Adjust EPP/EVA ratio based on control vs power needs
- Options de surface: T700 Carbon Fiber, Kevlar hybrid, or Titanium face sheets
- Custom Shapes: MOQ as low as 50 paddles for new mold development
- Edge Guard + Handle Build: Flexible layout for grip feel and branding
With these options, we help you develop performance-driven OEM Gen 5 pickleball paddles tailored to your brand’s identity and target players. Whether you serve control specialists, power hitters, or balanced all-rounders, our team ensures every detail is built with precision.
Support for Small Batch Launches & Pro Series Development
PKZK supports low minimums and flexible production runs, making it easy to test flagship models without committing to large volumes. From pro signature lines to branded limited editions, our low-MOQ options help you go to market faster—with lower risk.
Every paddle is backed by strict quality control, pro-level performance tuning, and export-ready packaging. We’ve built Gen 5 paddles for brands across North America, Europe, and Asia—including growing markets like Malaysia—and we’re ready to do the same for you.
Want to develop your next high-end paddle line? Start here: pagaies de pickleball personnalisées.
