We were approached by a client in America to address one of the biggest challenges in the pickleball industry: the noise generated during play. This was a big issue as pickleball courts are generally situated inside of residential estates resulting in frequent noise complaints in the surrounding area.

Research and Testing
In a team Over 40 samples, inspired by research papers, material databases, and practices from other sports industries, were tested. Samples were attached to a fixed replica handle, and a ball was dropped from a set height, adhering to IFPB standards. The most promising samples were selected for further iteration based on the results.

After promising initial research, I decided to pursue a web-based design. Inspired by tennis, which faces fewer noise complaints due to lighter rackets and perforations, I aimed to incorporate these features into pickleball paddles. The challenge was to maintain the paddle's feel and performance while reducing noise.

Rapid Prototyping
The first challenge was scaling the sample material to fit a full-size racket head. I tested two approaches: a repeated smaller web pattern and a single large web. After evaluating both designs, I chose the large web approach, as it provided significantly greater consistency. The smaller web introduced dead spots caused by the internal walls, which negatively affected performance.

Next, I focused on improving the consistency and feel of the racket, as it lacked the accuracy of a traditional pickleball paddle. To address this, I extruded the outer face of the web to be level with the frame, creating a flat hitting surface. This adjustment significantly enhanced the racket’s playability and durability. Additionally, this design change improved manufacturability by providing a completely flat surface on one side of the paddle.

This design was further enhanced by adding a second mirrored web to the back, ensuring both hitting faces had a consistent flat surface.

Project Outcomes
Overall, the project was a success. The design reduced the impact sound to a level lower than the noise generated by the ball hitting the court surface, effectively eliminating impact sound as the primary source of noise while maintaining a high level of playability. We presented our findings to the client through a formal presentation as well as sending the 3d printed bat to her. They are now further developing our designs with the intention of incorporating some features into their commercial product range.