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This video is about the process of making a Deep Apnea Carbon Fiber Fin blade. It is Part one of two videos by Ron and Ed, made for Oceanific Inc, who will be distributing the fins and bladed throughout the Caribbean. The fins are made by Ed, who is a **free diver and free diving instructor**. The company is currently based in Islamorada, Florida, and will soon be located in Central Florida. Deep Apnea currently manufactures *four different models of free diving fins* and is working on a **fifth model, a scuba fin**, which will be officially unveiled at DEMA. There is **no carbon fiber fin on the market specifically for scuba diving**, and Ed receives many customer requests for one. Fins are **built in-house**. Materials include: **3K carbon fibers**. Fiberglass. **Aramid (Kevlar)**, which can be used for strengthening where carbon fiber might break, though it is very difficult to work with and is only used for specific customers. All products used in manufacturing, including the rubber rail, paint, carbon fiber, and resins, are **manufactured in the United States**. Specifically, resins and rubber rails are from Florida, and carbon fiber is made in looms in the Northeast. A *high-strength epoxy* primarily used in boat building is used, which has been blended for quick catalysis and incredible strength. The fins have a **matte finish**, as opposed to a glossy finish seen on many other fins. Deep Apnea aims to *squeeze out as much resin as possible* during manufacturing. Resin does not provide strength; it only binds the fibers together. More resin can retard the fin's reflex, making it slower to pop back. *Manufacturing Process - Hand Layup and Pressing:* The process involves a **hand layup**, where a sheet of carbon fiber is literally laid on the mold and wet with epoxy. Ed describes this as "old school" and "good old-fashioned arm and leg work". This hand-on approach ensures *quality control* for every blade produced, as each fin is handled and inspected multiple times by a person, with no machining involved. A single fin can have *nine different laminates* inside it, including top, bottom, and several staggered panels. They use various fabrics beyond the plain weave visible on top, such as **unidirectional, triaxial, and biaxial**. After wetting the fin panels, the mold is closed and placed into **20-ton presses**. A specific amount of pressure is applied using a gauge and torqued to a specific foot-pound. Applying too little pressure can result in a fin that weighs more due to excess resin, while too much pressure can damage the product. *Achieving Different Stiffness Levels:* The stiffness of the fin (soft, medium, hard) is controlled by the **number and placement of different internal panels or laminates**. For example, adding a specific panel might make it a medium fin, while adding another could make it a hard fin. For **extra stiff fins**, custom work might involve shrinking a panel to allow for additional layers. Ed notes that custom work for extra stiffness is not common because existing fins have undergone extensive testing. *Testing and Target Users:* The company was **built around free dive spearfishing**. Deep Apnea fins are tested by a large spearfishing community in Islamorada, including *commercial spearos* who use the fins five to six days a week. These commercial spearos were the core customers when the company was formed and have used the fins for "thousands and thousands of days". Competitive free divers also use their fins in competitions. For the new scuba fin, Ed plans to *give prototypes to two or three dive masters* in the area to use every day for two to three months, aiming to get **"300 days of data"**. *Important Use Recommendations:* Deep Apnea fins have a **steep angle of 28 degrees**, which, when combined with fasteners, can create stress, torque, and pressure points on the bottom of the fin. This can lead to *cracking if walking around on a boat deck* with the fins on. It is recommended to *put the fins on while seated* (e.g., on the gunnel or swim platform) and then back roll or slide into the water. These specific free diving fins are **not recommended for scuba divers**, which is why the new scuba fin is being introduced.