How We Test Our Pickleball Paddles — And Why It Matters
A pickleball paddle can look great on paper. Carbon fiber face, advanced core, the right thickness — check, check, check. But specifications only tell part of the story.
At TOCO67, testing helps us understand how a paddle actually behaves. How much energy does the face return? How flexible is the construction? How much friction does the surface create? And does the finished paddle match the dimensions and characteristics we designed it for?
That’s why our paddle development process goes beyond choosing materials. We use a series of physical tests to evaluate performance, consistency and construction before a paddle reaches its final form.
Why Test a Pickleball Paddle?
Small changes can make a surprisingly big difference to a paddle.
A different carbon layup, core density, surface treatment, resin system or thickness can change power, stiffness, spin and feel. Even when two prototypes look almost identical, their measured characteristics may be different.
Testing gives us objective data to use alongside on-court feedback. Neither replaces the other: a machine can measure a paddle, but ultimately a player still has to like playing with it.
Here are some of the tests we use during paddle development and evaluation.
1. PBCoR Testing — Measuring Energy Return
PBCoR stands for Paddle Ball Coefficient of Restitution. In simple terms, it measures how the paddle and ball interact during impact and how much energy is returned to the ball.
This matters because modern paddle construction can produce very different levels of rebound. Core materials, face stiffness, foam systems and construction methods can all influence how energetic a paddle feels.
PBCoR testing gives us a controlled way to evaluate that response instead of relying only on descriptions such as “powerful” or “poppy.”
Why we test it: to better understand the power and rebound characteristics of a paddle and to evaluate the finished construction against relevant performance requirements.
2. Deflection Testing — How Much Does the Paddle Flex?
A paddle is not completely rigid. When force is applied to the face, the construction deflects — or bends — by a measurable amount.
During a deflection test, controlled pressure is applied to the paddle while its movement is measured.
This gives us information about the stiffness of the complete structure. Face material plays a role, but so do the core, thickness, layup, bonding and overall construction.
It is one reason two paddles both described as “16 mm carbon” can feel completely different.
Why we test it: to evaluate structural stiffness and compare different prototypes and constructions objectively.
3. Surface Roughness Testing — Measuring the Texture
Run your fingers across different paddle faces and the difference can be obvious. Some are almost completely smooth, while others have a pronounced texture.
Surface roughness testing allows that texture to be measured rather than judged by touch alone.
This is particularly useful when comparing raw carbon, peel-ply textures and other surface treatments. It also helps us understand whether different production samples are giving us a consistent finish.
And importantly, the carbon material itself doesn't automatically determine surface roughness. A T700 carbon paddle, for example, can have different surface characteristics depending on how it is manufactured and finished.
Why we test it: to quantify surface texture and check consistency between different finishes and samples.
4. Surface Friction Coefficient — Grip Is More Than Roughness
This is where things get especially interesting.
A surface that feels rough isn't necessarily the surface that creates the most useful interaction with a pickleball.
A friction coefficient test measures the resistance created when surfaces move against each other. This gives us another way to evaluate the functional grip of a paddle surface.
Roughness and friction are related concepts, but they aren't interchangeable. Surface material, texture and finish all contribute to the final interaction.
Why we test it: to better understand how different surface constructions create friction instead of simply assuming that “rougher is better.”
5. Reflection & Gloss Testing — Yes, That Matters Too
Performance isn't the only consideration. The visual finish of a paddle matters as well.
A gloss meter measures how much light is reflected from the surface. This allows us to compare matte, semi-matte and glossier finishes objectively.
For us, this is partly about design consistency. A black carbon paddle that is supposed to have a deep matte appearance shouldn't suddenly arrive with a noticeably glossy face.
Reflection is also relevant when evaluating a finished paddle against equipment requirements designed to prevent distracting reflective surfaces on court.
Why we test it: to evaluate the final finish and make sure appearance isn't left entirely to subjective judgement.
6. Paddle Sizing — Millimetres Matter
This one looks simple, but it shouldn't be skipped.
We measure the finished paddle's dimensions, including length and width, to make sure the manufactured product matches the intended design.
Shape affects much more than appearance. Changing the dimensions can alter reach, aerodynamic feel, weight distribution and the location of the sweet spot.
It is also essential that the finished paddle remains within the applicable dimensional requirements.
Why we test it: to verify that production matches the design and that the finished dimensions remain within the required specifications.
Testing vs Playing: We Need Both
Laboratory measurements are incredibly useful, but they can't answer every question.
A machine can tell us about deflection, friction or energy return. It can't tell us whether a paddle feels intuitive during a fast kitchen exchange or whether a player likes the feedback on a third-shot drop.
That's why we see testing and play testing as two different parts of the same development process.
Measurements tell us what the paddle is doing. Players tell us what that actually feels like.
Why This Matters When Comparing Paddle Materials
Testing has also taught us not to put too much weight on individual buzzwords.
T700 tells you something about the carbon fiber. 16 mm tells you something about thickness. PP honeycomb or foam tells you something about the core. And terms such as raw carbon or grit tell you something about the face or its finish.
None of them, on their own, tells you exactly how the finished paddle will perform.
What matters is how those elements work together — and that is exactly where testing becomes useful.
From Prototype to Court
Developing a paddle is a process of testing, comparing and refining. Sometimes a construction that sounds perfect on paper doesn't produce the result we expected. Sometimes a small change in surface, core or layup makes a noticeable difference.
That's part of the reason we test.
We don't just want to know what materials are inside a paddle. We want to understand what the finished paddle actually does.