Insight: Core and Aqua Dynamics

How did the partnership with Aqua Dynamics first come about and why did CORE choose to work with them over other factories?

The partnership was born out of a personal connection. CORE founder Bernie Hiss first met producer Frank Ulmer during his training at a well-known windsurfing brand. At the time, Frank was on a kind of world tour, looking to win customers for his relatively young company, Aqua Dynamics. Years later, Bernie remembered the man who had started a sail manufacturing business somewhere in Sri Lanka, and the two reconnected.

At that point, we had had some less-than-ideal experiences with board production in the Far East, so the idea of partnering with a German-managed company really appealed to us. Preparations started soon after, and both our team and the people in the Sri Lankan factory were introduced to one another. We’ve been working closely together ever since.

What convinced us even more was that Aqua Dynamics wasn’t just manufacturing sails – they were also producing a wide range of other high-performance products and materials, including paragliders, where safety standards and manufacturing tolerances leave absolutely no room for error. This combination of startup mentality, high-precision craftsmanship, entrepreneurial thinking, and a distinctly German approach to quality and process made it clear to us: Aqua Dynamics was the only right partner for this project.

And the best part – what makes us happiest – is that we’re still working with the same people as back then.

Tell us about the first kite model and how did production build up from there?

We then sent a small team to Sri Lanka – one of them was Frank Ilfrich, who, to this day, remains our kite designer. The task was anything but simple: our first planned product – still under the CARVED brand at the time – was a purebred C-kite, meticulously engineered for wakestyle, the discipline closest to our hearts.

It was a tough road. Aqua had never built an inflatable kite before, and we had no background in sailmaking. When the first proud photos arrived by email, we were in shock – hands on heads, thinking, “This is never going to work.” The reputation of our original brand was on the line, and failure was simply not an option. But what we saw didn’t meet our expectations at all.

There were even rumors that the team in Sri Lanka considered throwing in the towel more than once due to our high demands. But Aqua Dynamics’ relentless drive – combined with our shared obsession for perfecting every last detail and the perseverance to see it through – paid off. After more than 18 months, the first production units of our very first kite, the CARVED Unit, finally arrived at our headquarters. First five, then ten, then more and more.

They are now the world’s largest production facility for kites and wings, with CORE as their closest partner. Do you feel proud to have been involved with them for so long? And was there ever an opportunity or desire for the factory to produce kites for CORE only?

We feel incredibly proud to be the brand that started the kite success story with Aqua Dynamics. Other brands that followed us there can also appreciate what we’ve collectively gone through – the improvements in staff, systems, and overall production quality have evolved significantly, especially in collaboration with CORE.

Of course, we would love to call it a CORE-only factory. But especially as Aqua has scaled its capacity to meet our demands, we fully understand the need for consistent year-round utilization to keep things running sustainably – also in times when we’re not in production.

What is the working relationship like and how often do you visit?

We’ve built strong relationships on multiple levels. The most regular contact happens through our kite and wing designers, who visit the factory several times a year to work on new projects, ensure production quality, and optimize processes. In parallel, our sourcing team is in constant communication to coordinate production planning.

What stands out most is how warmly we’re welcomed every time – far beyond the typical supplier-client relationship. After so many years of working together, including knowing each other’s families, visiting Aqua often feels more like catching up with friends.

With all the new materials on the market, how have you worked together to develop the new manufacturing techniques required to utilize them?

We see it as a shared responsibility to never rest on our achievements. While CORE focuses on product innovation and performance, Aqua ensures that the latest materials and processes are implemented in a way that fully meets our quality standards. It’s a constant back-and-forth of ideas, testing, and refinement.

Paint a picture for us of what the factory is like. What other sports are they producing gear for?

It’s almost impossible to describe in words. Every time one of us – some with CORE for over two decades – visits Aqua, we’re amazed at how much it has grown and evolved.

Let me try: picture a production hall as long as two football fields, lined with four rows of tables, sewing machines, and hundreds of concentrating but laughing sewers. That’s just the kite section, where canopy panels and airframes come together. Add to that dedicated departments for cutting, printing, bladders, and more. The kite/wing division alone counts around 500 people – the largest unit at Aqua.

Beyond kites and wings, Aqua also produces sailboat sails, windsurf sails, paragliders, and even highly technical products for industries like medical equipment such as advanced paramedic backpacks.

How important is social responsibility to you when it comes to working with Aqua Dynamics? How have you ensured that they are fulfilling best practice?

This has been a priority for us from day one – back in 2005 when we first considered kite production. But we’ve never needed to impose or enforce anything: Aqua has consistently ranked among Sri Lanka’s top employers in terms of working conditions. Their management set out early to lead by example.

The result? Clean, spacy, light workplaces, above-average wages, on-site canteen, healthcare, traditional tea breaks, organized transport, education programs – and most importantly, a workforce that looks healthy, happy and proud to be there. You can feel the difference when you walk through the door.

How did CORE and Aqua Dynamics celebrate their 20 years of working together? Was there a big party?!

That’s another area where CORE and Aqua really connect: celebrating! Both companies are known for their legendary annual parties. So when there’s a reason to celebrate together – things can get wild. Look at the photos! It started with traditional dance performances and heartfelt speeches… and quickly escalated into a full-blown party with live music and nearly everyone dancing. Definitely a night to remember!

Do any of the Aqua Dynamics staff kitesurf? Do you or they do any testing in Sri Lanka?

Yes, some Aqua staff – including a few from the production team – do kitesurf. That said, Sri Lanka’s best kite spot, Kalpitiya, is a few hours north of the factory in Negombo. It’s a long, hectic trip even by car, so not part of daily life for most employees. But whenever our R&D team is on-site, they definitely take the chance to head north and put prototypes to the test in local conditions. Nothing beats real-time feedback in the field.