What Are Pickleballs Made Of | The Secret Sauce in 2024

As Pickleball becomes more popular, players are starting to ask “What are pickleballs made of?”. And the answer isn’t as simple as “plastic”. Although, technically it is correct.To the casual player, all pickleball balls look the same. But they don’t play the same. From factory floor to the store, there are a few ingredients that make the Pickleball “special sauce”.

And the key ingredient in that sauce is the materials used.In this article, we take a closer look at the materials used in pickleball balls. We dig into the composition, how it is made and we uncover the complex simplicity of different types of pickleballs.Let’s kick it in.Pickleball balls are made from different hard, durable and lightweight plastics.

The most widely used and popular of these plastics is polyethylene and polypropylene.The plastic material used will depend on the type of ball in production.Polypropylene (PP): A lightweight durable plastic that is often used for outdoor pickleball balls but it is used for indoor balls too. This material is resistant to impact, and it has a good balance of stiffness and flexibility.

It is perfect for outdoor play where rough surfaces and weather is always a factor.Polyethylene (PE): This is another common plastic that is mostly used for Indoor Pickleball balls. This material is slightly softer than Polypropylene. But it still provides great impact resistance when playing indoors.

PVC/Plastic: These are more basic plastic materials used for non-branded, budget friendly balls. These balls are suitable for casual play by beginners. They do not offer the same durability, performance or consistency as the balls made from Polypropylene and Polyethylene.Now that we know what Pickleballs are made of, let’s take a look at how they are made.

There are two ways to make a Pickleball, by using Rotational Molding or Injection Molding.Let’s take a look at the differences.1.Summary: These balls are produced in one piece with no seam on the ball.How Are they Made: Plastic is poured into a mold that is rotated in an oven until it is set. Once the plastic has cooled, the holes are drilled into the ball using an automated drilling machine.

Ball Details: The Rotationally molded balls are more expensive to make, but they are generally more durable. The ball flight is seen as more consistent because there are no seams on the ball. And every ball is exactly the same because of the automated technology used to produce them.2.Summary: These balls are produced in two pieces with a seam on the ball.

How Are They Made: Plastic is poured over two halves of a mold and then they are fused together and a seam is created on the inside of the ball.Ball Details: The Injection Molded balls are cheaper to make as no drilling is required. The uneven thickness of the ball can lead to less predictable ball flight and bounces.

These balls are also more prone to cracking and performance issues.Looking at what Pickleballs are made of (materials) and how they are made, (mold type), we can discover some interesting insights. Especially if we compare the most popular Pickleball balls and map them out using these two factors, material and mold type.

It is interesting to note that ball manufacturers like Franklin use both methods of ball production.The outdoor X-40 is rotational molded and is made from polypropylene (one piece with hard plastic).Both of these balls are USAPA approved for tournament play and follow the strict USAPA Pickleball specifications.

But let’s look at some more details.The X-40 and X-26 balls both weigh 0.A 12 pack of X-40 balls are roughly 15% more expensive than a 12 pack of X-26 balls. This is likely due to the rotational molded manufacturing process (which is more costly).The X-26 indoor balls are disliked by some players because they (allegedly) break too easily (two pieces with a seam).

This point illustrates that two balls that are almost identical, with the same material and weight BUT with a different manufacturing process, can impact three major components of the ball.Durability of the ball.That is why Pickleball manufacturers spend millions on research to innovate, and find that “special sauce” to create the perfect ball with superior performance and durability.

Speaking of special sauce, let’s take a look at advancements in pickleball ball technology.READ MORE: Pickleball Beginners looking to learn the Pickleball ball basics, start with What Ball is Used for Pickleball. The perfect starting place to learn about Pickleball balls.If you look at the History of Pickleball Balls, we can clearly see the evolution over the last 50 years.

And innovations continue to be made every day. Pickleball manufacturers like Franklin, make continuous improvements to their “secret sauce” of ball production. This includes the resin used, the cook time for balls amongst other factors.Some manufacturers like, Onix, have tried something new. The latest Onix Dura Fast 40 is an aerospace designed ball with two sizes of holes drilled in the ball for “true flight”.

And it is the “fastest ball made for the sport” of pickleball.And the Wilson Tru-32 Ball has a patented 32-hole design. This is engineered to improve ball flight and bounce consistency. It uses the injection-molded process (two pieces molded together) using a propriety plastic formula. This design “limits rebound decay and helps maintain a crisp feel off the paddle.

This is just a taste of the latest pickleball ball innovations. Manufacturers are dedicated to improving their own “secret sauce”. As they all strive to improve ball performance via research, new materials, innovative design and improved construction capabilities.And it can only get bigger and better from here.

And that’s a wrap. When you understand what pickleballs are made of, and the process to engineer and manufacture the ball, you can really appreciate it. The search for the perfect materials to make an indestructible ball, that has a consistent bounce and true flight, at a great price… continues.

We hope that you enjoyed this one. And like the Bros, you got a lot out of understanding the different materials used in balls, how they are made and ultimately, the end result. The Pickleball you hold in your hand come game time.The Aussie Pickleball Bros.This extensive research list was used to research the materials in a pickleball, how pickleballs are made and then individual ball manufacturer details to how they made their unique pickleballs.