Image of a person making a surfboard
Jeff Berting

I Make Earth-Friendly Surfboards

Ryan Harris makes surfboards without making waste

By Rasha Aridi
From the May/June 2025 Issue

Learning Objective: Students will summarize how and why a surfboard maker designs Earth-friendly surfboards.

Lexile: 840L; 550L
Other Focus Areas: Human Impacts, Engineering, Measurement & Data
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Jawad Chabib 

Ryan Harris surfs almost every morning before starting his workday.

Every morning, Ryan Harris rolls out of bed by 5:30 a.m. He’s up early to surf the waves in the Pacific Ocean along the coast of Los Angeles, California. Harris surfs on a one-of-a-kind board that he made himself. “One of the things I love most is that I get up and go surf on something I made with my own hands,” he says.

Harris is the owner of ECObyRy, a company that creates sustainable surfboards. He makes boards out of recycled materials and supplies, which reduces harm to the environment. Harris started surfing more than 20 years ago. But he later found out that the materials used to make surfboards are dangerous to the people making them—and harmful to the planet. Harris spoke with Scholastic about inventing a safer and Earth-friendly way to build surfboards.

Ryan Harris gets up by 5:30 a.m. every morning. He lives along the coast of Los Angeles, California. He’s up early to surf the waves in the Pacific Ocean. Harris rides a one-of-a-kind board. He made it himself. “One of the things I love most is that I get up and go surf on something I made with my own hands,” he says.

Harris is the owner of ECObyRy. It’s a company that makes sustainable surfboards. They’re made from recycled materials and supplies. That helps the environment. Harris started surfing more than 20 years ago. But he later found out some surfboard materials are toxic. They can harm the people making the boards. And they can hurt the planet. Harris spoke with Scholastic about inventing safer and more Earth-friendly surfboards.

How did you become a surfboard designer?

I studied design in college. Later, I moved to Los Angeles and fell in love with surfing. I started painting boards. Then I learned how to make them. I had no idea I would be doing this as a career, but now I’m a surfboard maker and designer.

I studied design in college. Later, I moved to Los Angeles. There, I fell in love with surfing. I started painting boards. Then I learned how to make them. I didn’t know I’d be doing this as a career. But now I’m a surfboard maker and designer.

What inspired you to design Earth-friendly surfboards?

The process used to make most surfboards isn’t good for the environment. The inside of a board is usually a type of flexible plastic called polyurethane (pah-lee-YUR-uh-thayn) foam. It’s difficult to recycle, so excess materials end up in landfills. This waste pollutes the soil, air, and even water.

On top of the foam is a layer of a woven material called fiberglass. It’s a strong, lightweight material made of plastic and bits of glass. Then the board is sealed with a liquid called resin that hardens as it dries. A gas escapes from the resin when you use it, and that gas is very unhealthy for workers to breathe in.

When I learned all of this, I knew I had to find a better way to make boards. So I started trying to figure out a solution.

The way most surfboards are made isn’t good for the environment. The inside of a board is usually polyurethane (pah-lee-YUR-uh-thayn) foam. It’s a type of flexible plastic. It’s hard to recycle. So leftover materials end up in landfills. This waste pollutes the soil, air, and even water.

Fiberglass goes over the foam. It’s a woven material. It’s made of plastic and bits of glass. It’s strong and lightweight. Then the board is covered with resin. This liquid hardens as it dries. A gas escapes from the resin when you use it. And that gas is very unhealthy for workers to breathe in.

I learned all of this. And I knew I had to find a better way to make boards. So I started looking for a solution.

Ryan Harris

Harris shreds scraps to make into items like vases and coasters.

How did you design surfboards that were better for the environment and for workers?

It was a lot of trial and error to test different sustainable materials. But now we have a process that’s safe and reduces waste. To float, a surfboard must be less dense than the water around it. This means the board needs to have less matter in a given space than water has.

Each surfboard begins as a rectangular block of foam, called a blank. We use Styrofoam, a lightweight plastic foam that can be recycled at special recycling centers. We sculpt the foam both with machines and by hand to create the shape. Then we coat it with a resin that comes from plants and isn’t harmful to breathe in. After that, we sand the board smooth. Our boards surf just as well as the traditional ones! We also take scraps from our process and turn them into new products—keeping the waste out of landfills.

It was a lot of trial and error. I had to test many sustainable materials. But now we have a process. It’s safe and reduces waste. A surfboard needs to float. So it must be less dense than the water around it. This means the board needs to have less matter in a given space than water has.

Each surfboard begins as a rectangular block of foam. It’s called a blank. It’s made of Styrofoam. It’s a lightweight plastic foam. It can be recycled at special recycling centers. We sculpt the foam. We use machines and our hands to create the shape. Then we coat it with a special resin. It comes from plants. And it isn’t harmful to breathe in. We sand the board smooth after that. Our boards surf just as well as the regular ones! We also take scraps from our process. We turn them into new items. That keeps waste out of landfills.

How else do you reduce waste?

Jeff Berting

Mealworms break down leftover Styrofoam.

We reuse nearly 100 percent of our waste to make other products. Leftover Styrofoam can become new boards. We toss other materials—like extra resin, plastic bottles, and even old surfboards—into a plastic shredder to create a superstrong material called “shred.” We make and sell coasters, trays, key chains, and special surfing tools out of the shred. A neighboring company uses our shred to make skateboards too.

We even have mealworms that eat and break down Styrofoam dust into safer substances! Their poop can be used as soil. Anything we can’t reuse goes to a special recycling center. Our workshop is the world’s first zero-waste surfboard factory!

We reuse nearly 100 percent of our waste. We turn it into other things. Leftover Styrofoam can become new boards. We shred other materials. That includes extra resin, plastic bottles, and even old surfboards. We use it to make a really strong material. It’s called “shred.” It becomes coasters, trays, key chains, and surfing tools. A nearby company also uses our shred. It makes skateboards.

We even have mealworms. They eat and break down Styrofoam dust. They turn it into something safer! Their poop can be used as soil. Anything we can’t reuse goes to a special recycling center. Our workshop is the world’s first zero-waste surfboard factory!

Do you have advice for aspiring makers?

At first, people thought using broken boards to make new ones was crazy. Don’t listen to people who tell you that you can’t do something. Try
to figure out ways to reduce and reuse your waste. We’re getting great ideas from the next generation, so get fired up!

People thought my idea was crazy at first. That’s because we used broken boards to make new ones. Don’t listen to people who tell you that you can’t do something. Try to figure out ways to reduce and reuse your waste. We’re getting great ideas from young people. So get fired up!

video (1)
Activities (4)
Answer Key (1)
Step-by-Step Lesson Plan

1. PREPARE TO READ (5 minutes)
Activate prior knowledge and draw conclusions about surfboard shapes.

  • Project a few photos of surfboards and invite students to share what they know about surfboards and surfing. Ask: What do you notice about the shape of surfboards? Why do you think they are shaped that way? (e.g., They are flat on the top so someone can stand on them.) Ask students to predict what surfboards are made of. Note their ideas on the board.

2. READ AND Reflect (25 minutes)
Read the article and evaluate its main ideas and key details.

  • Preview the STEM vocabulary. Then read the article aloud, pausing after each section to discuss key details and the section’s main idea. As a class, have students summarize the article’s main idea.
  • After reading, ask: What materials are used to make most surfboards? (polyurethane foam, fiberglass, and resin) Compare students’ predictions of surfboard materials from step 1 with the materials mentioned in the article. (If students predicted plastic, note that polyurethane and resin are types of plastic and fiberglass contains plastic.) Then ask: What are Ryan Harris’s concerns about these materials? (They can’t be recycled, and resin can release dangerous gases.)
  • Watch the video “What Is Engineering?” Ask: Is making surfboards an example of engineering? Why or why not? (Yes, because it requires thinking about a problem and designing a solution.) What criteria did Harris set for his surfboards? (They must float and support a person.) What constraints? (They can’t be made with nonrecyclable or dangerous materials.)

3. RESPOND TO READING (30 minutes)
Investigate properties of different materials and use them to design a surfboard.

  • To broaden available materials for the hands-on activity, you can collect clean items that are headed for recycling or the trash ahead of time.
  • Preview the Engineering on the Job: Surfboards activity. Discuss your expectations for how students will responsibly handle the water. If desired, you can set up one or two bins of water in one area and have groups complete their float tests one at a time. You may want to have students test materials in groups (steps 1-3) and then transition to working in pairs or individually for their surfboard designs (step 4). Once they have completed the activity, reconvene to discuss their designs and results.

Text-to-Speech