Series 04.

Diving into the making of the Pro Staff, Wilson uses pre-preg carbon sheets to provide maximum strength in the rackets. The carbon sheets are pre-impregnated with resin and stored at a cool temperature to stabilize the resin. This prevents the resin from curing prematurely. For Wilson to create such stability in their racket, they utilize layered sheets, ensuring every single fiber is intentionally placed.

So, how are these molds made? An inflatable bladder is placed into the frame and pressurized. This pressure will force the carbon sheets to push outward, against the mold walls, resulting in a hollow frame. This hollow frame provides a geometry that is consistent with the wall thickness. Variance in pressure means variance in stiffness. Wilson’s bladder molding process minimizes variance. This is why the two Pro Staff frames from different productions will provide an identical in-hand feel.