By Simona Moore | Former professional tennis player and founder of PBPRO
Pickleball paddle technology is evolving. Traditional polypropylene honeycomb cores have been popular for years, while full foam core pickleball paddles introduce a different approach to construction and feel. What's the difference, and which should you choose?
Table of Contents
What Is a Honeycomb Core?
Many pickleball paddles use a polypropylene honeycomb core: a lightweight network of hollow cells between the paddle faces. This proven construction can deliver predictable response, touch, control and accessible pricing.
PBPRO Signature Plus 16mm — Honeycomb Construction
The PBPRO Signature Plus combines a 16mm polypropylene honeycomb core with a T700 raw carbon fiber face and cold-pressed construction. Designed for improving and intermediate players, it offers a controlled feel, spin potential and all-court versatility at $54.99.
What Is a Full Foam Core?
Instead of a hollow honeycomb structure, a full foam core paddle uses an engineered foam-based interior. Manufacturers can select materials, densities and reinforcements to tune stiffness, vibration response and impact feel. Not every foam-core paddle uses the same construction, and foam alone doesn't guarantee superior performance.
EPP vs. EVA Foam Explained
EPP — Expanded Polypropylene
EPP is a lightweight, resilient foam made from expanded polypropylene beads. Its ability to compress and recover makes it useful in impact-management applications. In a pickleball paddle, it can contribute to responsiveness, a tunable impact feel and resistance to repeated compression.
EVA — Ethylene Vinyl Acetate
EVA is a flexible foam used in athletic footwear and sporting equipment. As a surrounding layer in paddle construction, its density and placement can influence vibration damping and impact feel. EPP and EVA serve different functions and can complement each other.
Full Foam Core vs. Honeycomb: Comparison
| Feature | Honeycomb core | Full foam core |
|---|---|---|
| Structure | Hollow polypropylene cells | Engineered foam interior |
| Feel | Familiar and predictable | Tunable by material and density |
| Control | Excellent in control-focused designs | Can be engineered for control |
| Power | Depends on complete paddle | Depends on complete paddle |
| Vibration | Varies by construction | Foam can influence damping |
| Durability | Depends on bonding and materials | Depends on foam, frame and bonding |
| Pricing | Wide range | Often premium positioned |
Does full foam automatically mean more power or durability? No. Weight, stiffness, face material, balance, frame reinforcement and manufacturing quality all matter.
Inside the PBPRO Infinity Gen-X5
Full Foam. Full Performance. | $199 | Coming November 2026
PBPRO Gen-X5 combines a full EPP foam core, white EVA foam surround, double carbon fiber frame and T700 raw carbon fiber face. Together, these elements are engineered around four performance goals: responsiveness, control, power and durability.
How the Construction Works
- Full EPP foam core: A resilient internal structure designed to contribute to responsive feel and controlled power.
- White EVA foam surround: A surrounding layer intended to influence vibration damping and impact comfort.
- Double carbon fiber frame: Reinforcement designed to support stability and structural durability.
- T700 raw carbon fiber face: A performance-oriented surface that supports spin-focused play.
These are engineering goals, not independently verified claims that Gen-X5 outperforms every honeycomb paddle. The Gen-X5 is USA Pickleball approved and expected to launch in November 2026.
Explore PBPRO Infinity Gen-X5 → (Coming November 2026 — product page not yet available)
Which Paddle Technology Is Right for You?
Choose honeycomb if you value familiar, predictable performance and excellent value. The Signature Plus 16mm is an accessible option for improving players.
Consider full foam if you're an intermediate or advanced player interested in premium construction and a different impact feel. The Gen-X5 (Coming November 2026 — product page not yet available) offers PBPRO's full foam core architecture.
Frequently Asked Questions
What is a full foam core pickleball paddle?
It uses a foam-based internal structure instead of traditional hollow honeycomb cells.
Is full foam better than honeycomb?
Not automatically. Both can make excellent paddles; design and personal preference determine the best fit.
What is EPP foam?
Expanded Polypropylene is a lightweight, resilient foam that can be engineered for responsive internal structures.
How is EPP different from EVA?
EPP is an expanded polypropylene foam; EVA is a flexible ethylene-vinyl-acetate foam. They have different mechanical properties and can serve different roles in a paddle.
Do full foam paddles generate more power?
Not necessarily. Power depends on the complete paddle design, not the core material alone.
Are full foam paddles approved for tournaments?
Approval depends on the individual model. PBPRO Infinity Gen-X5 is USA Pickleball approved.
When is Gen-X5 available?
It is expected in November 2026 at a planned retail price of $199. Check the product page for availability.
Final Thoughts
Full foam core technology creates exciting new engineering possibilities, while honeycomb remains a proven choice for control and value. For intermediate players, Signature Plus 16mm offers strong value at $54.99. For players exploring premium foam construction, the Infinity Gen-X5 (Coming November 2026 — product page not yet available) introduces EPP, EVA and reinforced carbon framing.
