The Evolution of Pickleball Paddles – From Wood to Full Foam Part 2

Gen 3 – Thermoformed “Floating Core” Paddles (Foam-Infused Honeycomb, 2023–Present)

Gen 3 paddles take thermoforming a step further by altering the inside of the core itself with additional foam layers or sections, creating a “floating core” or suspended honeycomb design. The goal was to solve some Gen 2 durability issues and push power and sweet spot to the max. The result is a paddle that feels plush yet powerful, often with even more “trampoline” effect, albeit sometimes at the cost of new challenges.

• Construction: Still fundamentally a thermoformed unibody (carbon fiber + honeycomb + foam all fused). The difference is that Gen 3 introduces foam inside the honeycomb core, not just at the edges. How? Different brands approached it in various ways: The construction still uses polymer honeycomb for some structure, but more foam is integrated throughout the paddle’s interior in ways that create extra elasticity. Everything is still hot-pressed together as one piece, often with venting or special layups to avoid the Gen 2 air pressure issues (e.g., Ronbus Nova paddles introduced a permeable carbon grid in the edge so the paddle isn’t fully sealed, preventing internal pressure build-up). So Gen 3 could be seen as thermoform 2.0, with smarter construction to maximize performance and mitigate prior issues.

  • Some placed a thin foam layer between the face and the honeycomb core (covering part of the interior). This effectively “decouples” the core from the face slightly, allowing a bit of give, like a suspension. JOOLA’s new line (often referred to as Joola “3” or “3S” series) used what they call a “Charged Foam” injection, creating a propulsion layer in parts of the core for extra pop.
  • Others put foam columns or pockets within the core. Imagine alternating sections of foam and honeycomb, so that when the ball hits, some honeycomb areas can flex more independently, cushioned by surrounding foam. This is what some refer to as a “floating poly core”; the poly core isn’t one solid piece across the entire face; it’s segmented or supported by foam. The Pickleball Apes “Pulse” and 11six24 “Power” series, for instance, attach the edges of the poly core to foam, so the core kind of floats inside.
  • A brand called Gearbox, known for edgeless carbon paddles, introduced a Pro Power series, which doesn’t use a traditional honeycomb at all (Gearbox cores are carbon fiber rib structures), but they incorporated an internal foam element to increase the trampoline effect to compete with these other Gen 3s. The Gearbox CX14H “Ultimate Power” is an example – not honeycomb, but the feel and result (huge pop) is similar to the foam-honeycomb hybrids, so it’s grouped in this generation.

• Key Features: Extreme power and enlarged sweet spots are the hallmark. By suspending parts of the core with foam, these paddles act almost like a spring within a spring. The term “floating core” is often used because the honeycomb core can deform more on impact, cushioned by the foam, then rebound, adding extra kick (a trampoline effect). This elasticity means big power on hard swings – Gen 3 paddles can be rockets. At the same time, the foam also dampens vibrations very well (more comfort), and on softer shots, the paddle can feel very gentle (almost a pillow-y feel on dinks). Dwell time on the face is increased – the ball stays a tad longer, which gives a controlled feeling on soft shots or rolls, despite the paddle’s liveliness on drives. Sweet spot is typically massive; foam in the core helps distribute the impact such that even areas in the middle of the face that might have been “dead” on a normal honeycomb now have some spring. Essentially, Gen 3 paddles tried to give players everything: power, spin, control, and comfort in one. However, pushing this envelope led to some paddle models flirting with or exceeding limits (and durability/reliability was still catching up early on).

• Performance Characteristics:

  • Power – simply put, a good Gen 3 paddle crushes the ball. When you take a full swing, the combination of a stiff frame and an internally elastic core can slingshot the ball with incredible speed. Some Gen 3 users reported that even with a 16mm thick paddle, the ball comes off as fast as a much thinner one – that foam is storing and returning energy efficiently.
  • Spin remains top-tier because they all have those raw carbon faces.
  • Control on soft shots is surprisingly good (better than Gen 2 in some opinions) because of increased dwell time, the foam gives a cushioning effect on soft impact, so you can feel the ball on the paddle longer when dinking or rolling a drop volley.
  • Forgiveness is excellent: you can hit near the edge or slightly off-center, and the result is very close to a perfect hit. The paddle feels very stable (any twist is absorbed by the multi-material core). Many players describe Gen 3 paddles as having a “plush” or ultra-smooth feel – soft when you need soft, explosive when you swing hard. In other words, the paddle’s response becomes more dynamic based on your input: gentle touch yields gentle output, hard swing yields big output. Ideally, that’s the dream. However, these benefits depend on the construction quality, any inconsistency, and you could get weird hot spots or, worst case, delamination issues. And indeed, Gen 3 had some of that…

• Pros:

  • Huge Power on Demand: Gen 3 paddles are scary powerful when you want them to be. For players who struggled to put away balls, these paddles provide a new gear. Even a defensive block can become an offensive shot with a little push, due to the trampoline effect. This level of power can make the game easier for certain players (e.g., those who don’t swing super fast can still generate depth and pace).
  • Great Spin & “Hold”: The ball bite on these paddles is excellent. You get the full advantage of the raw carbon plus the foam-induced dwell time, which gives you more spin and control on placement. Advanced players love that they can shape shots, heavy topspin passes, or sharp cut angles, and the paddle grabs the ball enough to execute them consistently. It’s like the ball sticks for an extra millisecond to let you impart spin.
  • Expanded Sweet Spot (Edge to Edge): Gen 3 minimized the difference between hitting center and near the edge. The additional foam and structural tweaks mean fewer mishits feel bad. A lot of the face plays “hot”. One could argue that some Gen 3 designs achieved the largest sweet spots ever in pickleball paddles up to that point. Confidently attacking or defending balls slightly off-center becomes more feasible.
  • Comfort & Vibration Dampening: These paddles tend to be arm-friendly. The foam and flex absorb shock, reducing the impact transmitted to your hand. Even when you crush a ball or accidentally hit near the edge, the vibration is muted relative to stiffer Gen 2 paddles. This is a big plus for folks with tennis elbow or sensitivity – you get performance without the pain.
  • Innovative Problem-Solving: Gen 3 showed paddle makers addressing the Gen 2 delamination saga head-on with engineering. Venting edges (like Ronbus’s grid) solved internal pressure build-up. Tuning foam placement solved some inconsistencies. It’s a pro that the industry learned and adapted, making Gen 3 not just more powerful but potentially more reliable (with proper design).
  • Tailored Models: The “foam in core” concept allowed brands to fine-tune paddles more. For example, JOOLA released different versions (3, 3S, etc.) presumably with varying foam configurations for control vs power. We also saw multiple thickness offerings (some with super-thick 19mm cores still playing powerfully). This gave players more options to find the perfect fit.

• Cons:

  • Early Durability/Quality Issues: Pushing the limits did mean some Gen 3 paddles had consistency problems or failures. The more complex internals introduced new failure modes: some paddles experienced internal foam shifting or core cracking. And yes, core crush/delamination was still reported on certain models. For example, there were talks of some ultra-powerful paddles becoming too lively (like essentially partially delaminated) after a few weeks of heavy use. The foam expansion and extra flexibility, if not perfectly controlled, could still lead to the face separating or the core collapsing under stress, especially in heat or with improper curing. So, reliability wasn’t 100% solved. Some players went through warranty returns due to these issues in early Gen 3 launches.
  • Floating Core Issues: Since the Core is not attached, it's hard to control these paddles and giving the direction where you want to hit.
  • Over-the-Top Power (Control Risk): Not everyone could handle these “rocket launchers.” The trampoline effect is a double-edged sword – if your technique or timing is off, you might sail balls long until you adjust. Players coming from a control paddle could find Gen 3 too much initially. A few paddles like Joola Mod TA-15 came out so hot that rumors swirled about them being banned. The Kitchen blog even referenced one (the “MOD” paddle) and a Gearbox model as being so power-loaded that they were on the verge of not passing specs. So, there’s a learning curve to harnessing the power and some risk that a particular model might get flagged for exceeding limits (e.g., if it has a sneaky delam).
  • Soft Game Adjustments: While dwell time is improved, the bounce on very soft shots can still be unpredictable if the core is super springy. Some players felt that touch shots from Gen 3 paddles, especially if using a very elastic core design, required extra finesse – the ball could still sometimes pop up if not careful (though this was generally an improvement over Gen 2). It’s a minor con, and many adjusted, but worth noting that not everyone instantly became a soft game master with these. Touch still requires touch – the paddle just gives a different feel that you must dial into.
  • Cost & Availability: These were top-of-the-line tech, often priced at the high end ($250+). Also, initially, only a few models (often from smaller boutique brands or in limited runs) had the true Gen 3 tech, making them hard to demo or get. If you did get one, chances are you paid a premium. As big brands catch up, this is improving, but in 2023, some of the hyped Gen 3 paddles were constantly sold out or only available via pre-order.
  • Weight Management: With so much going on (extra foam, etc.), some Gen 3 paddles ended up slightly heavier or head-heavy to accommodate the foam and reinforcement. While many still fall in standard weight ranges, players very sensitive to weight distribution had to pay attention. Adding foam internally can shift the balance. However, this is quite model-specific – some are fine, but a con to be mindful of for those picky about weight/balance.
  • Complex Construction = Complex Failures: If something goes wrong internally, it’s not easily noticeable from the outside. A Gen 3 paddle might look fine, but play “funky” if, say, a foam section didn’t bond right. This is rare, but the complexity means if you got a lemon, it’s not something you could fix – warranty is the route. Simpler paddles either worked or broke; these could potentially have subtle issues affecting play (like one area of the face a bit softer). Manufacturers are improving QC to minimize this.

Notable Examples: JOOLA 3 14/16 (2023), these introduced JOOLA’s foam-injected “Charged Carbon” cores and were used by pro Ben Johns for a time. They exemplify the Gen 3 philosophy: thermoformed, foam-enhanced for more power (Perseus being the power model, Scorpius more control). Since Joola 3 was banned by USAPA, they just recently launched the toned-down Gen 3 power paddles with the Pro IV series. 11Six24 Power Paddles and Pickleball Apes Pulse are niche brands explicitly marketing “suspended core” designs with foam injection. Ronbus Ripple paddles used the 3D carbon fiber lattice with EVA foam to eliminate delam and still keep power, a Gen 3 approach focused on durability as well. Gearbox Pro/Power Series – Gearbox is unique (no honeycomb), but their Power series was lumped into Gen 3 because it achieved a similar leap in pop and had some internal tweaks; Gearbox’s lack of honeycomb in general foreshadows Gen 4 (solid core) design too. By late 2023, other big players hinted at or released Gen 3-like tech: Selkirk had prototypes (Labs Project 006/007 perhaps) with foam integration, and Adidas (which entered pickleball) teased some techy paddles as well. It’s a rapidly evolving space; new Gen 3 style paddles were popping up frequently as everyone tried to max out the trampoline while staying legal.

Playstyle Impact: Gen 3 paddles, in the hands of the skilled, further accelerated the game. Offense got another boost – driving the ball with heavy spin became even more effective because these paddles could generate put-away pace from tougher positions (e.g., a shoulder-high ball that previously you might just roll safely, now you might hammer it and still drop it in the court with spin). Defense paradoxically also improved for some – you could block a hard shot and, with the paddle’s liveliness, turn it into a counter. The term “easy power” is often used; players who might have been defensive or soft by necessity could suddenly attack more because the paddle gave them that extra oomph. On the flip side, control-oriented strategists had to adapt to opponents hitting heavier balls and had to ensure their paddle wasn’t too bouncy for their touch. The game saw a bit more dichotomy: some embraced the full power game, while others started seeking ways to get back more control (foreshadowing Gen 4). Additionally, because Gen 3 tech pushed boundaries, there was a lot of conversation about paddle testing and legality. In high-level play, you’d see referees frequently checking paddles for delamination or illegal power. This era made everyone much more aware of the equipment – it became as much a tech race as a skills contest. Importantly, Gen 3 also planted the seed that perhaps the honeycomb core itself was now the limiting factor, which leads to the next revolution…

Gen 4 – Full Foam Core Paddles (No Honeycomb, 2024–Beyond)

The CRBN #1 TruFoam Genesis is one of the first true Gen 4 paddles. It swaps the traditional honeycomb for a 100% foam core*, wrapped in carbon fiber. This new core design aims to eliminate weaknesses like core breakdown and dead spots.* Gen 4 paddles are built entirely (or almost entirely) from a solid foam core, without any honeycomb structure. This is a radical shift in construction that promises more consistency, longevity, and a unique playability that could redefine the game.

• Construction: No polypropylene honeycomb at all. Instead, the paddle’s core is a single solid (or sometimes layered) piece of high-density foam, usually some type of polymer foam like EVA or polyurethane engineered for performance. The foam core is cut or molded into the shape of the paddle. Around this core, the face materials (carbon fiber, fiberglass, etc.) are applied and cured. The entire paddle may still be thermoformed in a sense (heat/pressure used to bond the face to the foam core and form the edge), but since the core itself is foam (which can be heat-pressed too), the result is effectively a one-material core spanning edge-to-edge. Many designs include continuous foam to the edge (no separate edge guard, though sometimes there’s an edge bumper or a different density foam at the edge for protection). Some Gen 4 paddles incorporate cutouts or sections in the foam to fine-tune weight and flex. For example, the CRBN TruFoam Genesis core is a solid foam block with engineered cut-outs to adjust its playability. Selkirk’s Project 008 uses a proprietary “PureFoam” and even offers different thicknesses (10, 13, 16mm) using the same foam material. The foam used is high-density to maintain structure, not the squishy foam you find in cushions, but more like a hard foam that still has some give. There is no honeycomb, no hollow cells – so no internal air gaps or weak points like cell walls. It’s a homogeneous core. This is similar to how some tennis rackets have foam inside or how some table tennis paddles use a solid sponge, but it’s new for pickleball paddle dimensions.

• Key Materials: Proprietary performance foam is the star. CRBN hasn’t fully disclosed its foam recipe, but it’s designed to resist deformation (crushing) and maintain spring. Selkirk’s PureFoam is described as a high-density foam that flexes on impact but doesn’t permanently deform easily. These foams are likely closed-cell EVA or similar, offering a balance of rigidity and bounce. The face is still typically carbon fiber (raw carbon for spin) because that’s the best face material we know for high-level play. Interestingly, CRBN added a fiberglass layer in the center of the face of their TruFoam paddles to boost “pop” in the sweet spot – since foam cores can feel softer, a bit of fiberglass can reintroduce some kick. So Gen 4 paddles may mix materials in the face to get the desired power/control mix. Edges might just be the foam core itself (possibly a bit denser on the outer rim for durability) or a small edge protection tape. All Gen 4 so far are also edgeless by design (no hard edge guard).

• Performance Characteristics: The makers of Gen 4 claim a combination of greater consistency, longevity, and a unique balanced performance.

  • Consistency: Because the core is solid foam, there are no dead spots or hot spots from honeycomb inconsistencies – the ball should rebound similarly no matter where you hit on the face. The sweet spot effectively spans almost the entire paddle face because the foam’s energy distribution is uniform.
  • No core fatigue: Foam doesn’t “crush” like honeycomb polymer can; it tends to rebound back. Over time, it should maintain its pop much longer, meaning the paddle’s playability on day 100 is like day 1 (no more worrying about “my core is shot”).
  • Power: A well-designed foam core can be made plenty powerful; however, early indications (CRBN, Selkirk) suggest they moderated the wild trampoline to prioritize control and consistency. The power is described as more controlled, not as “spring-loaded” as a Gen 3 paddle. You can still hit hard, but you might have to supply a bit more swing – the foam gives a strong, controlled push rather than a pingy bounce.
  • Spin: Foam cores increase dwell time (the foam slightly compresses on impact), so the ball stays on the paddle face a bit longer, allowing more spin to be imparted. Combined with carbon faces, Gen 4 paddles are absolute spin machines (CRBN’s testing showed over 2100 RPM, among the highest ever measured).
  • Control: Probably the standout feature – players report a very connected feel on soft shots. The foam flexes just enough to give you feedback and a sense of the ball on the paddle, leading to tremendous confidence in placement. It’s almost like the best of both worlds: a stiff carbon face for precision but a soft underlying core for touch.
  • Sound is often a lower-pitched “thud”; foam cores have a distinct, more muted sound (which incidentally is community-friendly for noise). Overall, Gen 4 paddles feel stable, solid, and predictable. They don’t have random hot spots, and they don’t go dead in the sweet spot over time. It’s like every part of the paddle is the sweet spot, and the performance is tunable by foam density.

• Pros:

  • Durability & Longevity: Perhaps the number one advantage, no more core cracking or compressing. The foam core is highly resistant to the kind of breakdown that poly honeycomb experiences. This means a Gen 4 paddle should maintain its pop and feel for a much longer lifespan. Players can “say goodbye” to the days of a paddle getting mushy or dead after a few months of heavy use. Also, without internal voids, there’s less risk of large-scale delamination; nothing to collapse internally. This reliability could save money in the long run, as you won’t need to replace paddles as often due to performance loss.
  • Consistent Huge Sweet Spot: The entire face plays consistently. You can hit an inch from the edge or dead center and get a very similar response. Dead zones (like often near the handle or edges on honeycomb paddles) are essentially gone. This is massive for competitive play, as mishits are far less penalized. It also gives confidence to go for shots, your paddle will respond as you expect, even on those reach shots or reflex volleys slightly off-center.
  • Enhanced Control & Feel: The foam core increases dwell time, the ball stays on the paddle a hair longer, giving you a sense of holding it, which translates to superb control over placement and spin. Selkirk’s 16mm Project 008, for example, is noted as one of their most forgiving, control-oriented paddles ever, with a very smooth feel. Touch shots, resets, blocks, you name it, are easier to execute with consistency. Players coming from Gen 2/3 often say Gen 4 feels a bit softer, more predictable, which boosts their soft game without really sacrificing power.
  • Plenty of Power (Optimizable): While initial Gen 4 offerings prioritize a balanced power (not unwieldy), they still pack a punch. The foam can be engineered in different densities, meaning manufacturers can create a spectrum from control-biased to power-biased models easily by tweaking foam stiffness. CRBN’s foam paddle, for instance, has enough pop for aggressive play but intentionally less than the craziest Gen 3 trampoline paddles, giving a controllable power. And as the tech matures, we could see foam cores that rival or exceed Gen 3 power while still being stable. So power is by no means lacking – it’s just more controlled currently. Also, no honeycomb means no “honeycomb shape” influence on power – the energy return can be very uniform.
  • High Spin Potential: All Gen 4 so far use raw carbon fiber surfaces, so they inherently have top-tier spin. Plus, the foam flex allows even more grip on the ball. CRBN’s TruFoam is cited as one of the highest spin paddles tested. Spin is a given, you’re not sacrificing any RPMs by going foam. If anything, second-generation raw carbon plus foam might set new spin records (with the caveat that USA Pickleball might keep an eye on that if it gets extreme).
  • Strategic Material Layering: Gen 4 introduces the ability to do things like what CRBN did – adding a fiberglass layer in the sweet spot to juice the power. This is easier to implement on a solid core. That means paddles can be really engineered for desired outcomes (e.g., more pop in the center, more control at the edges, etc.). We’ll likely see more clever designs like this, which is exciting for future paddle customization.
  • Noise Reduction: As a minor pro, foam cores tend to produce a more muted sound. While not a performance factor, it’s community-friendly (some pickleball paddles are loud; these are a bit quieter, potentially easing noise complaints at clubs or neighborhoods).

• Cons:

  • Slightly Less “Raw” Power vs Gen 3: Early feedback indicates that while Gen 4 paddles have plenty of pop, they aren’t as outrageously bouncy as some Gen 3 were. This is intentional to give more control, but players who love the absolute most explosive paddles might feel Gen 4 is a tad toned down in the power department. In other words, you might have to swing a Gen 4 a bit harder to generate the same pace that a Gen 3 might have given easily. For many, this is a worthwhile trade-off, but for pure power players, it’s a consideration. (It’s worth noting that “lack of power” is relative; these still hit very hard, just with more player input.)
  • New Feel to Adjust To: A solid foam core feels different. Some describe it as a more dampened, solid contact – almost like the ball sinks in and then is catapulted out smoothly, rather than a crisp pop. This can take adjustment if you’re coming from a hollow honeycomb feel. It’s neither good nor bad, just different, but traditionalists might need a little time to get used to the slightly muted sensation. One might miss a bit of that crisp feedback of hitting a ball on a hard honeycomb.
  • Weight Considerations: Foam cores can be made light, but making a big solid foam paddle that’s structurally sound might result in a bit heavier paddle or more head-heavy feel if not engineered carefully. CRBN’s TruFoam paddles are around 8.0–8.5oz, which is standard, so this might not be an issue after all. But if someone tried a super thick foam core, the weight could creep up. So far, not a huge con, but we’ll see as designs proliferate.
  • Cost: These paddles are introducing brand new materials and processes, and currently sit at the top of the price range. We’re talking ~$250–$300 for the first wave (CRBNs are 279, Selkirk Labs 008 was $288 in their limited release pack). As with any new tech, early adopters pay a premium. Over time, economies of scale may bring prices down, but for now, Gen 4 is an investment.
  • Limited Track Record: Being so new, we don’t have long-term user data on how these paddles hold up after 1-2+ years. The promise is they’ll be more durable, but it’s fair to be a little cautious. Will the foam lose a bit of bounce after thousands of hits? Will the face adhesion stay solid? Thus far, lab tests and company assurances are positive (foam is more resistant to breakdown), and initial reports are good, but time will tell. Early CRBN foam users are quite happy with longevity anecdotally.
  • Fewer Options (for now): As of early 2025, only a couple of companies have full-foam paddles available (CRBN’s TruFoam line and Selkirk Labs 008). Players who don’t snag those have to wait, as other brands haven’t released Gen 4 yet or are still prototyping. So if you want one, you might be limited to specific shapes/brands until the market offerings expand.

Notable Examples: CRBN TruFoam “Genesis” Series was launched late 2024/early 2025; these were the first widely available Gen 4 paddles. They come in the CRBN¹ (elongated), ² (square), and ³ (hybrid elongated) shapes, all featuring the full foam core. They immediately garnered attention for their consistent feel and promise of no core wear. Selkirk Labs Project 008; Selkirk’s experimental release (early 2025) featuring a full foam core (PureFoam) in three thickness variants (10mm for power, 13mm hybrid, 16mm control). Selkirk’s take is slightly different: they aimed for maximum control and feel, with the thicker versions being remarkably soft and the thinner still providing power but with the foam’s signature consistency. Other brands: HUDEF, Body Helix (the smaller companies) have an EVA-core paddle on the market as well, indicating even more entrants. Gearbox hasn’t announced foam core (they use carbon cores), but their power series shows the appeal of non-honeycomb designs. Expect in 2025 that major brands like JOOLA, Engage, Franklin, Honolulu, Chorus, etc. will unveil their foam core prototypes, it’s the logical next step now that two big players have broken the ice. Even some new startups are likely to jump straight to foam core designs, given the buzz. We’re at the start of the Gen 4 era, so many examples are yet to come.

Playstyle Impact: Gen 4 paddles could reshape the meta of pickleball in subtle but important ways. The immediate effect is consistency and confidence. Players can trust their paddle to behave the same way every time, and not to slowly lose pop over a season. This encourages developing touch and precision, because you know a well-placed dink today will feel the same off your paddle next week or next month, no adjustments for a “softening” core. Also, with essentially the whole face usable, we might see even more aggressive volleying and creativity, as players aren’t afraid to utilize every inch of their paddle face for shots. The slightly reduced “free power” (compared to Gen 3) might slow the game marginally from the unsustainable arms race of trampoline paddles, which could bring a bit more emphasis back to strategy and placement. As one reviewer noted, players used to the most spring-loaded paddles might initially find Gen 4 underwhelming in raw pop, but they’ll likely appreciate the control and precision they gain. In high-level play, this could mean longer rallies and more strategic points, as the equipment is less prone to wild variances (no surprise flyers off a delaminated paddle, etc.). For recreational players, foam paddles offer a “buy it and enjoy it for a long time” appeal – less fuss about the paddle going dead, more focus on the game. As the tech matures, we could eventually see foam cores that also dial up the power more, potentially giving us everything at once. But even the current Gen 4 models already allow heavy hitters to hit hard (just with a bit more effort, which arguably is how it should be) and touch artists to shine. In essence, Gen 4 might bring a sort of equilibrium: very high performance but in a controlled, predictable package. And as always, the cycle continues – players will push this new tech to its limits, and we’ll see what the next innovation brings. But one thing is clear: full-foam cores have opened a new frontier in paddle design, one where the limitations of 20-year-old honeycomb may finally be fully overcome.