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The introduction of GEN 3 pickleball paddles has been one of the most significant innovations in the sport. These paddles dramatically improved spin and power, quickly gaining popularity among players. However, as more players adopted them, durability issues became apparent—after just 1-2 months of use, many paddles suffered from delamination, core crushing, and structural breakdowns.
In this review, we’ll explore how the EVO01 solves these problems through advanced material engineering and construction, setting a new standard for GEN 3 performance.
Part 1: What is a GEN 3 Paddle?
GEN 3 paddles stand out by incorporating EVA foam between the polypropylene (PP) core and the paddle’s edge. This creates a "diving board" effect, enhancing energy absorption and release (similar to a tennis racket’s stringbed).
Why Do GEN 3 Paddles Break Down?
The problem lies in core compression and foam softening over time. To understand why, we need to examine GEN 3 manufacturing processes:
1. Semi Thermoformed Process (e.g., Joola MOD TA-15)
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The PP core and carbon fiber face are bonded at room temperature.
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The core is then cut, and EVA foam is inserted.
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A short thermoforming cycle shapes the paddle’s foam edge wall.
2. Thermoformed Process
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The EVA foam and PP core are pre-assembled before thermoforming.
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A longer, high-temperature press forms the paddle’s structure.
The EVA Problem
GEN 3 paddles typically use two types of EVA foam:
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High-Rebound EVA – Expands during thermoforming, then shrinks at room temperature, creating micro-gaps and voids inside the paddle.
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Heat-Resistant EVA – Holds its shape better after molding but still suffers from plastic deformation under repeated impact (like an EVA shoe sole flattening over time).
Result? The foam collapses, losing its structural support, leading to core crushing and delamination.
Part 1: How We Solve GEN 3 Durability Issues
In Part 1, we explored why traditional GEN 3 paddles fail—EVA foam breakdown, core crushing, and delamination. Now, let’s dive into how the Pakle EVO01 redefines durability through material science, structural engineering, and precision manufacturing.
1. Material Innovation: Thermoplastic Elastomer (TPE)
The EVO01 replaces EVA foam with a proprietary thermoplastic elastomer blend. Unlike EVA, which deforms permanently under pressure (like a worn-out shoe sole), TPE offers:
✔ Near-perfect rebound – Retains elasticity even after thousands of hits.
✔ No plastic deformation – Resists "flattening" over time.
✔ Consistent performance – Eliminates the "break-in period" where GEN 3 paddles lose tension.
Why it matters: While EVA weakens after repeated impacts, TPE’s molecular structure ensures long-term stability, preventing core collapse and dead spots.
| EVA | Thermoplastic Elastomer | |
| Rebound rate | 40-80% | 70-95% |
| Rebound Velocity | Slow (with obvious lag) | Very fast (instantaneous rebound) |
| Energy loss | High (part of the energy is converted into heat and dissipated) | Low (high energy storage and release efficiency) |
EVA deformation can cause core crushing
2. Structural Upgrade: Dual Diving Board Design
The Pakle EVO01 features the Vortex Core:
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Primary Diving Board – Controls power delivery, preventing excessive "trampoline effect" (a common GEN 3 complaint).
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Central Foam Layer – Enhances face stability, delivering a consistent solid feel and expanded sweet spot.
Why It Matters:
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Traditional GEN 3 paddles lose tension as foam degrades, causing erratic bounces.
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The Pakle EVO01’s vortex core ensures predictable ball response throughout its lifespan.
3. Precision Manufacturing: Low-Temp Thermoforming
115°C (239°F) Curing Process
Most GEN 3 paddles use high-temperature presses (140°C+), which stress materials and accelerate breakdown. The Pakle EVO01’s low-temperature thermoforming:
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Reduces Internal Stress: Minimizes delamination risk.
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Preserves Core Integrity: Prevents PP honeycomb crushing.
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Pre-Treated Elastomer: Lab-tested to account for thermal contraction, ensuring zero post-molding warping.
Proven Reliability: testing shows 30% less edge deformation vs. other gen3 paddles after 10,000 impacts.
Why the PAKLE EVO01 is the Ultimate GEN 3 Paddle Upgrade
After rigorously testing and analyzing the PAKLE EVO01, one thing is clear: This is the most advanced, durable, and performance-driven GEN 3 paddle on the market.
Who Should Buy It?
✅ Competitive Players – Want consistent power/spin without durability issues? The EVO01’s TPE core and dual diving board structure ensure long-term reliability.
✅ Power Players – The optimized rebound gives explosive drives while maintaining control.
✅ Spin Specialists – The stable face and enlarged sweet spot enhance brush and whip techniques.
✅ Players Fed Up with Broken Paddles – No more delamination, core crush, or dead spots after a few weeks.
Key Advantages Over Competitors:
🔹 Unmatched Durability – Thermoplastic elastomer outperforms EVA, resisting deformation.
🔹 Engineered Consistency – Low-temperature thermoforming prevents internal stress failures.
🔹 Tournament-Ready Control – The dual flex system balances power and precision.
🔹 No Break-In Period – Unlike traditional GEN 3 paddles (which require weeks of play to stabilize), the EVO01 delivers tournament-ready performance right out of the box.
Final Recommendation:
If you’re serious about performance and longevity, the PAKLE EVO01 is worth every penny. It fixes the critical flaws of traditional GEN 3 paddles while delivering elite-level playability.
