Since early 2024, we have been working tirelessly to make PHA (Polyhydroxyalkanoate) a viable material for disc golf discs.

PHA is created when microbes ferment renewable feedstocks such as corn, sugarcane, vegetable oils, and even used cooking oil or other waste streams. After extraction and purification, the resulting biopolymer can be blended with other materials to improve strength, durability, and processing performance.

On its own, PHA presents significant challenges for use in high-impact applications like disc golf, including brittleness, processing difficulty, and limited flexibility. To overcome these limitations, our upcoming formulation uses a PHA/PBAT blend that balances durability, consistent flight performance, and improved environmental impact. PBAT is an oil-based biodegradable polyester that enhances toughness and flexibility while still breaking down under the right composting or industrial conditions.

This blended approach allows us to introduce a more sustainable disc option sooner while continuing long-term development toward future material innovations. Our goal is to push disc golf toward more responsible manufacturing, starting with this new PHA/PBAT disc releasing in January 2026.

Our wood biocomposite discs use a blend of cellulose fibers, wood particles, and TPE to create a durable, high-performance material. The wood fibers and pulp residues come from sustainably managed forests and are combined with renewable polymers to reduce brittleness and increase strength. During production, the fibers are dispersed evenly, allowing the material to be shaped using standard injection molding and extrusion processes.

The addition of TPE enhances flexibility, impact resistance, and consistency while maintaining the environmental benefits of the biocomposite. The material is recyclable and energy recoverable, supporting circular-economy principles especially when incorporating waste byproducts such as crude tall oil and label residues. This blend provides reliable disc performance while significantly reducing overall environmental impact.

Our recycled plastic discs are made using a blend of GRS certified recycled TPE and standard TPE. By incorporating recycled TPE sourced from post-consumer and post-industrial waste streams, we reduce carbon emissions, divert usable material from landfills, and give it a second life as high-performance gear.

The addition of standard TPE helps maintain the durability, grip, and consistency players expect, ensuring the recycled material performs reliably without compromising feel or flight. GRS certification provides full material traceability and verifies that our recycled inputs meet strict global standards, supporting our mission to make disc sports more sustainable while delivering dependable quality.