en.Wedoany.com Reported - US-based Revolin Sports uses bio-based composite materials such as flax fiber and basalt fiber to manufacture pickleball paddles, aiming to enhance both athletic performance and environmental sustainability.
Company co-founder Hugh Davis started playing pickleball in high school and began repairing paddles. Later, while studying Materials Science and Industrial Engineering at the University of Michigan, he systematically researched advanced materials used in rockets, snowboards, Porsches, and Teslas. This experience led him to co-found Revolin Sports in 2019 with his sister Greta Davis and girlfriend Sophie Vandenbosch, with the core philosophy of manufacturing high-performance products that are both athlete-friendly and environmentally beneficial. The company chose pickleball as its first market to validate material technology and achieve economies of scale.
Revolin Sports has developed two primary material technologies for its paddle series: BioFLX, using flax fiber, and LavaFLX, using basalt fiber. Davis began researching bio-based materials while participating in the University of Michigan's Supermileage Vehicle team, obtaining samples of various sustainable raw materials including hemp, flax, and bamboo. He noted that these materials possess all the properties of fiberglass, with higher stiffness and better vibration damping, making them highly suitable for pickleball paddles. After extensive experimentation with processing methods, resins, core materials, and the angle and orientation of fiber layers, the company ultimately invented new material combinations and commercialized them.
The BioFLX paddle uses three layers of vertical flax fiber to provide five times better vibration damping than synthetic materials, with an additional horizontal flax fiber layer to enhance durability. The LavaFLX paddle is composed sequentially of one layer of basalt fiber, one layer of tightly woven fiberglass, and another layer of basalt fiber, balancing elasticity and power while expanding the sweet spot. The company also selected a rubber-toughened, low-temperature curing epoxy resin that is more energy-efficient, highly impact-resistant, and compensates for some deficiencies of natural fibers. Standard paddle core materials include honeycomb, balsa wood, and foam, with production methods recently shifting to single-paddle molding to optimize core structure. Both BioFLX and LavaFLX technologies are patent-pending, with the core involving the combination of core materials and fiber layers, as well as specialized scrims and adhesives to achieve good bonding between thermoset and thermoplastic materials.
According to Davis, compared to traditional carbon fiber-reinforced composites or fiberglass-reinforced composites commonly used in pickleball paddles, the carbon footprint of their bio-based composites can be reduced by up to 95%. Additionally, the excellent vibration damping properties make the paddle's hitting sound quieter, meeting the growing regulatory requirements of many communities regarding pickleball noise. Players also report that the elasticity of natural fibers helps reduce wrist and elbow injuries or conditions. According to 2025 statistics released by PickleRage, approximately 36.5 million people in the US have played pickleball at least once, with over 10,700 dedicated courts, and the market continues to grow. Against this backdrop, Revolin Sports has launched BioFLX+ material, which incorporates basalt into the flax fiber layer to increase power, and is researching recyclable thermoplastic composites while beta-testing a recycling program called "Rev Cycle Upgrade," aiming to take back products at the end of their paddle life, grind them into new products, and pass the cost savings on to consumers.
The company aims to sell 10,000 pickleball paddles in 2026 and plans to collaborate with manufacturers of other racket and board sports, marine, and office furniture to promote its innovative materials.
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