Fliteboard eFoil: Gliding Over Water, with Support from Mastars-News

Open water, salt, UV, impacts

Fliteboard is an electric-powered hydrofoil, also known as an eFoil, from the Australian brand, recognized by Red Dot, Australian Good Design Awards, and the German Design Award. It rides lakes, rivers, and coastal seas where salt, spray, UV, and impacts are daily realities—demanding rigorous sealing and micron-level tolerances.

Each stage—design → prototype → mass production → delivery—needs integrated control. At Mastars, we turn Flite ideas into real, growth-driving products.

The scenario of eFoil demands higher process standards from the manufacturer, photo credit by Flite

Sealing, micron tolerances, lightweight aluminum

This is a pure-electric product used on water; if tolerances, design, manufacturing, or quality slip, the experience suffers.

The difficulties during prototyping are:

• Aluminum-alloy weight reduction: cut mass yet keep stiffness, fatigue life, corrosion protection.
• Carbon-fiber battery-tube sealing: pass airtight/salt-spray; failure risks short circuit.
• Tight interface fits: control stack-ups at mast, fuselage, wings, battery bay.
• Marine exposure: finishes/polymers must resist salt, UV, and impacts.

If this were a single part, it might be easy; Fliteboard is a complex assembly—Mastars must one-stop resolve all prototyping hurdles before volume.

Crafted down to every detail during prototyping

Buyer-first sealing, cheaper at scale

With certified systems (IATF 16949, ISO 9001, ISO 13485), Mastars closes every loop—design, manufacturing, quality. From a buyer's view, we chose internal spray coating + inner-wall polishing for the carbon-fiber battery tube: it achieves repeatable sealing without structural redesign and reduces total manufacturing cost.

In mass production, the seal tests pass consistently; process control across CNC, injection molding, assembly, and testing holds variation low.

The battery pack is perfect for water sealing because of a small change in the manufacturing process

Seal fix without redesign, fastest and lowest cost

The coating + polishing path avoids re-engineering the tube’s interior, shortens validation, and trims tooling rework—the most efficient and most cost-effective solution. Scrap and rework drop; takt stays stable; supply is one-stop. Today Mastars ships ~ 10,000 sets/year for Fliteboard. An integrated digital chain lets startups and SMEs move from proof to volume with clear accountability.

Boards are ready to be shipped across the sea

Customer-first certainty, from idea to scale

Open-water eFoils punish shortcuts. Mastars manufactures from the buyer's perspective. An easy yet efficient change in process delivers repeatable airtightness without redesign and at a lower cost.

With one-stop digital manufacturing from Mastars, small and medium enterprises and innovative teams can progress from idea to mass production with stable takt and predictable scale.

Fliteboard eFoil gliding over water, with support from Mastars, photo credit by Flite

Mastars, to be the most trusted and reliable one-stop services partner for low-volume digital manufacturing worldwide!