PP Honeycomb Core Overview

Development:

The Polypropylene (PP) Honeycomb Core emerged as the dominant technology in pickleball paddle manufacturing, largely supplanting earlier materials like Nomex and aluminum. Its development was driven by the need for a core that offered a more favorable combination of feel, weight, durability, and sound dampening compared to its predecessors. By thermally bonding sheets of polypropylene plastic into a cellular honeycomb structure, manufacturers were able to create a lightweight, resilient, and cost-effective core. This innovation set the industry standard, and for many years, the vast majority of paddles were built around this technology. It remains the benchmark against which newer innovations, such as foam injection and thermoforming, are compared.

Characteristics:

• Responsive & Lively Feel (“Pop”): The most defining characteristic of a PP Honeycomb Core is its lively and responsive feel. The honeycomb cells compress and rebound quickly upon impact, creating a distinct “pop” that provides excellent feedback for drives, volleys, and smashes. This allows for a direct and connected feel with the ball.
• Lightweight & Maneuverable: Polypropylene is an inherently lightweight material. This allows manufacturers to produce paddles across a wide spectrum of weights, making them highly maneuverable and ideal for players who value quick hand speed, especially during fast exchanges at the net.
• Cost-Effective & Accessible: The manufacturing process for PP honeycomb is highly refined and efficient, making it the most cost-effective core material. This accessibility is why it is used in paddles at every price point, from entry-level beginner sets to some performance-tier models.
• Distinct Auditory and Tactile Feedback: Players using a standard PP honeycomb paddle will notice a crisp, higher-pitched sound and a more direct transmission of impact vibrations to the hand. While this provides clear feedback, it offers less dampening compared to foam-based cores, which can be a consideration for players with arm sensitivity.

Uses:

The PP Honeycomb Core is the workhorse of the pickleball industry, serving as the foundational technology for a massive range of paddles. It is the go-to choice for players who prioritize a traditional and lively feel, maximum maneuverability, and a direct, unfiltered connection to the ball. It is particularly well-suited for players who do not have arm comfort issues and appreciate the immediate feedback it provides. Its versatility makes it suitable for nearly all playing styles, from baseline drivers to quick-handed net players, depending on the paddle’s other design elements (e.g., surface material, thickness).

Suitable Paddle Types:

• Beginner & Intermediate Paddles: The ideal balance of performance, durability, and affordable cost makes the PP Honeycomb Core the perfect foundation for paddles aimed at players developing their skills.
• Lightweight & “Speed” Paddles: Its inherently low weight makes it the natural choice for paddles designed for maximum hand speed and quick reactions at the kitchen line.
• Traditional Control Paddles: Many classic control paddles utilize a thicker PP core (e.g., 16mm or more) to increase dwell time and soften the impact, providing excellent touch and placement without the added weight and muted feel of foam.
• Value-Oriented Performance Paddles: Manufacturers often pair a standard PP Honeycomb Core with premium face materials (like raw carbon fiber) to offer high-end performance characteristics at a more competitive price point compared to thermoformed and foam-injected models.