23.04.2025

The skateboard start-up Kape has developed an innovative process for manufacturing skateboards from composite materials. KraussMaffei implemented the technical requirements for the mould carrier and supplied a specially customised machine. In a conversation with the responsible developers, we take a look at the origins and impact of this innovation.

In an interview with K-Mag, Peter Karacsonyi from Kape and Florian Jovanovitch from KraussMaffei talk about the challenges in the production process, the advantages of the materials used – and why plastics also shine at the skatepark.

COO Daniel Jahn (left) and CEO Peter Karacsonyi (right) rely on skateboards made from plastic composites. Copyright: Leo Rosas

From Idea to Implementation

Mr Karacsonyi, how did the idea of producing skateboards from composite materials come about?

Peter Karacsonyi: I’ve been passionate about skateboarding since I was a child and always wondered why we’re still using wood when modern materials offer much better properties. Wood breaks easily and has to be replaced often. I wanted to change that.

What makes the new materials so special?

Karacsonyi: We use thermoplastic composite materials with continuous fibres. These offer an ideal combination of flexibility, resilience and low weight. They’re also more durable and sustainable than traditional wood.

What challenges did you face in implementation?

Karacsonyi: The biggest challenge was developing a production process that makes optimal use of the continuous fibres while producing a board with the feel and mechanical properties of wood. The production also had to be economical and sustainable.

The Collaboration with KraussMaffei

Mr Jovanovitch, what role did KraussMaffei play in this project?

Florian Jovanovitch: Our task was to develop a special mould carrier that meets the high requirements for heat resistance and flexibility. The tool had to be able to rotate and open in all directions in order to realise the board’s complex sandwich structure.

What was the biggest technical challenge?

Jovanovitch: The processing temperatures ranged between 140 and 160 degrees Celsius, which is far above typical requirements. So we had to use heat-resistant components and ensure the process remained efficient.

How exactly does the sandwich structure work?

Jovanovitch: Continuous fibres are placed on the top and bottom of the board, while a lightweight foam core in the centre ensures stability. This combination of materials gives the board its exceptional strength and flexibility.

How did the collaboration with KAPE go?

Jovanovitch: We worked closely together, tested prototypes regularly and made adjustments. This iterative development was crucial to the success of the project.

Image: Skater mid-air during a trick, shot from a low-angle perspective – focus on the plastic deck skateboard; Copyright: Hannes Mautner

Kape team rider Levi Löffelberger tests the new plastic board under real conditions – and is convinced by its performance. Copyright: Hannes Mautner

The Result: A New Era for Skateboards

Mr Karacsonyi, how does the finished skateboard differ from conventional models?

Karacsonyi: Our board is more durable and resistant to breakage than wooden boards. It also retains its tension and pop characteristics for years.

How did professional skaters react to the new board?

Karacsonyi: Our team rider Levi Löffelberger was sceptical at first. He couldn’t imagine a plastic board having the same liveliness as a wooden one. But after several tests, he was convinced – and now rides nothing else.

How was the new skateboard received by customers?

Karacsonyi: The first edition sold out within a few hours. That shows there’s demand and people are ready to switch to more sustainable alternatives.

Sustainability in Focus

How sustainable is the new production process really?

Karacsonyi: We use recycled caprolactam, which is recovered from old fishing nets and carpets. This not only reduces waste, but also the demand for newly produced plastics.

What other sustainability benefits are there?

Karacsonyi: Our boards are produced in Salzburg. This avoids the long, energy-intensive supply chains of conventional wooden boards, which are often shipped halfway around the world. That saves huge amounts of CO₂.

How long does a Kape board last compared to a wooden board?

Karacsonyi: Our boards last eight to ten times longer. This significantly reduces the production and transport of replacement boards and saves over 90% in CO₂ emissions overall.

Image: Young man in a black overall holding a skateboard deck at a production machine in a workshop; Copyright: Kape

With support from KraussMaffei, start-up KAPE is bringing plastic composite skateboards to the streets. Copyright: Kape

Outlook and Scaling up

What are the next steps for KAPE and KraussMaffei?

Karacsonyi: We’re working on scaling up production and offering our boards in retail soon. The demand is huge and we want to meet it.

Do you see potential for this technology in other areas?

Karacsonyi: Absolutely. The possibilities range from the automotive industry to the production of structural components. The benefits of these materials are enormous.

The collaboration between Kape and KraussMaffei shows how established companies can support innovative start-ups. The result is not just a technologically advanced skateboard, but an important step towards more sustainable and efficient manufacturing processes.