The Awake Electric Surfboard RÄVIK and eFoil VINGA: High-Performance Watercraft with Innovative Battery Thermal Management

The aim was to develop a comprehensive material solution for electric surfboards and eFoils that addresses several key requirements: flame-retardant material, thermal management and insulation. Different functional areas such as cell holders, housings, mechanical connecting elements, and design elements should each be covered with optimally suitable materials to enable a holistic solution from a single source.

The material search for battery components focused on a material that could optimize thermal distribution while extending the lifespan of lithium-ion batteries to ensure lasting and safe driving pleasure.

While developing the energy storage system for the e-surfboards and eFoils, Awake was looking for an integrated material solution that would meet several essential requirements from a single source. Awake wanted to optimize the battery life and extend the usage time until the next charge. In addition, the solution had to ensure the high-quality appearance of a high-performance lifestyle product while meeting the increased energy efficiency requirements.

The challenge was to cover various functional, thermal, and mechanical requirements with suitable premium-performance materials - from the cell to the outer structure of the battery.

In addition, critical factors such as flame retardancy, thermal management, mechanical durability and optical properties had to be addressed in a single material class from a single source.

A tailor-made material combination from the Covestro portfolio has been implemented as the ideal solution. For the cell holder, Makrolon® TC120 FR was used – a thermally conductive, electrically insulating material that avoids hotspots and ensures homogeneous heat dissipation during charging and discharging cycles. This significantly extends the lifespan of the battery cells and allows for longer usage times per charge.

The battery housings were realized with Makrolon® 6487 and Bayblend® FR3042, which are characterized by high impact toughness and reliable flame protection – crucial for the safety of the e-surfboards and eFoils. For the LED displays and lighting components, Makrolon® LED5202 and RW6267X were used, whose high transparency and optimal light reflection support energy-saving LED integration and high-quality branding elements.

The mechanical rotary lock made of Makrolon® GF9415 provides the necessary rigidity and temperature resistance, while a combination of Makrolon® GF9415 and Desmopan® 9370AU TPU was used for the handle and flange bumper – ensuring optimal mechanical damping, durability, and a premium tactile feel that highlights the high-quality character of these electric high-end water sports devices.