The development and impact of the all-new Black Project Hydro SynergyX on the paddling market

The sport’s competitive edge is sharper than ever, driven by relentless performance optimisation. As specialisation takes centre stage, brands must do more than keep pace – they need to disrupt.
We’ve been witnessing new approaches to developing SUP-specific gear, influenced by the principles of design thinking and disruptive innovation. The SUP R&D (Research and Development) side seems to have embraced a guiding principle straight out of Silicon Valley: ‘Move fast and break things.’

Innovation in the sport is no longer about small, incremental changes – it’s about bold experimentation, pushing limits, and yes, ‘breaking things’ or as Chris Freeman, puts it, ‘breaking away from trusted norms.’

TotalSUP caught up with Chris Freeman, Co-Founder of Black Project, to explore the Maui brand’s R&D philosophy behind the all-new Hydro SynergyX paddle – a design that continues to prove it has an enduring grip on SUP athletes across the globe.

Hi Chris, are we moving away from versatility in paddle designs toward more performance-specific paddles? Does the SUP world need another high-performance paddle, and why are these designs becoming more specialized?

Specialization is a natural progression in all sports, and stand-up paddling is no exception. While versatile paddles like the Black Project Lava remain essential for a broad range of paddlers, the competitive side of the sport is increasingly driven by performance optimization. As racing evolves, both athletes and brands are continually seeking ways to maximize efficiency and performance.

Just as boards are fine-tuned for specific conditions and paddlers, so too can paddles and fins be optimized to extract the best possible performance. If we want to provide our athletes with every opportunity for success, we must continue pushing the boundaries of innovation. Different disciplines demand distinct techniques – what works for an explosive 100m sprint is vastly different from what’s needed for a 10-15km distance race. By designing paddles tailored to these specific demands, we enable paddlers to refine their technique, reduce fatigue, and ultimately perform at their best.

Are we at a point where we can apply the concepts of design thinking and disruptiveness—key drivers of innovation and industry transformation—to the SUP industry?

Absolutely. The principles of design thinking and disruptive innovation are already shaping the evolution of stand-up paddling, and Black Project is at the forefront of this shift. We don’t just iterate on existing designs—we challenge the status quo to create performance-driven solutions. In practical terms, this means starting fresh, making mistakes, learning, and growing as a design team.

With the Hydro SynergyX, we took a bold approach, breaking away from trusted norms. We had to rethink everything, even going back to the drawing board to redesign our construction from the inside out to achieve the desired shape, weight, flex, and performance characteristics.

Design thinking starts with understanding paddlers’ needs at the deepest level. By analyzing biomechanics, race conditions, and paddling efficiency, we can develop solutions that truly enhance performance. For the Hydro SynergyX, we listened carefully to athletes and customers, gaining insight into their on-water experiences and identifying ways to improve both performance and comfort. However, we believe this is only the beginning—more advanced technology and data capture are needed to truly understand paddler performance without bias or misinterpretation.

At the same time, disruptive innovation is about breaking away from traditional constraints. The SUP industry has long been dominated by conventional design thinking, but there is still a long way to go in unlocking the full potential of paddle and fin technology. Whether it’s through material advancements, shape optimizations, or entirely new production methods, every product we create is an opportunity to transform how paddlers experience the sport. By applying these principles, we are not just following trends—we are creating them.

Is the Hydro SynergyX, along with other Black Project designs, protected by patents?

No, we do not pursue patents. At Black Project, we focus our resources on innovation and product development rather than legal enforcement. Patents can sometimes slow progress, encourage complacency, and lead to unnecessary distractions. Instead, we believe that continuous innovation is the best way to stay ahead.

That being said, we’ve seen other companies attempt to copy everything from our designs to our marketing language, which, while frustrating, also confirms that we’re leading the way. If we weren’t setting trends, there would be nothing for them to copy.

Of course, copying the look of a paddle is one thing, but replicating the performance is another. We have taken strategic steps to ensure that our proprietary construction methods and materials remain confidential, making it impossible for competitors to duplicate what makes our paddles truly special. True innovation isn’t just about appearance—it’s about execution, materials, and expertise, all of which set Black Project apart.

Joep van Bakel winning the ICF World SUP Championship title with the Black Project Hydro SynergyX

You mentioned that the Hydro SynergyX paddle was developed over a 2-year period, in collaboration with Arthur Arutkin, Seychelle, Blue Ewer & your wider team. Why does it take so long? Could you also tell us more about the direct impact of the athletes on the design? Are there any specific features that could be “named” after them?

Put simply, everything changed, except the PowerGrip handle (which was developed alongside the Hydro SprintX). Originally planned as a one-year project, it extended to two years due to the depth of innovation required—not just for the paddle itself but also for the new branding, which we delayed so the Hydro SynergyX could be the first to showcase the updated look.

Athlete collaboration was crucial to the process. The Hydro SynergyX was built around our new Tour Carbon shafts, which serve as the foundation of the design. We wanted something radically different, requiring us to develop a completely new shaft system. This meant not only designing new molds but also refining stiffness and construction across a range of paddler needs—future-proofing our designs for both this paddle and future innovations.

Arthur Arutkin and Bernd Roediger played pivotal roles in driving the shaft concept forward, logging countless hours of testing and feedback alongside me. However, Blue Ewer, Christian Andersen, and Donato Freens were also instrumental in refining the shaft design. Unfortunately, Christian had to leave the team before the project was completed, and Blue later followed, both due to conflicts with their NSP contracts, which prohibited them from using Black Project paddles or fins.

That said, their contributions remain highly valued, and their feedback—drawn from diverse paddling styles and conditions—was essential in fine-tuning flex, responsiveness, and performance to better serve a wider range of paddlers. Their input is not forgotten, and we acknowledge their role in shaping this paddle.

Beyond the shaft, the entire team of athletes—including Arthur, Seychelle, Bernd, Christian, Donato Freens, and others—provided critical feedback. A standout testing session at the APP event in Portugal brought fresh insights from multiple paddlers, highlighting perspectives that Arthur, Bernd, and I might have otherwise overlooked.

The original blade concept evolved significantly throughout the process. Our normal approach involves making multiple 3D-printed and laminated prototypes, but due to the complexity of this project, we initially skipped some of those steps—a decision we later regretted. Instead, we opted for more mold iterations, leading to an extensive range of prototype paddles, some of which were extreme and required adjustments to find the right balance.

For context, creating a single prototype blade costs around $2,000 when factoring in design, molds, production, and shipping. Each round of development costs about $5,000 and takes 8-12 weeks, not including testing, and any refinement which can take 1-8 weeks depending on the availability of athletes or conditions. This cycle repeated until we were confident in the final product. It’s easy to see how two years can pass quickly when working through multiple concepts to achieve true innovation.

There were moments of doubt. I remember testing in the harbor with Bernd, feeling frustrated, and saying: “If we can’t make a better paddle, we might as well close the company – because I only want the best, and right now, this isn’t it!” But perseverance paid off. The Hydro SynergyX became more than we had hoped, both in paddler feedback and competition results.

Many will wonder why this process is so time-consuming, but as a small company, our resources are limited. Unlike large corporations with big budgets, extensive tooling, and dedicated R&D teams, Black Project is lean. I’m deeply involved in innovation, testing, sales, and operations, meaning I can’t always rush to the harbor for testing. Likewise, we can’t fly our athletes to Hawaii on demand—we must wait for the right opportunities.

Having Arthur based in Hawaii has been invaluable, allowing real-time discussions and on-water testing. Christian, Donato, and Bernd have also been fantastic assets—not just for their racing expertise but for their ability to push equipment to its limits in diverse conditions.

Yes, we could speed up development, but doing so would require a significant cost increase, something beyond the scope of a small, independent brand like Black Project. Instead, we prioritize quality over speed, ensuring every new product is a true game-changer rather than just another iteration.

Who is the new Hydro SynergyX aimed at?

The Hydro SynergyX is designed for paddlers who want to get the most out of their performance, whether they’re racing, training, or just pushing themselves to go faster and paddle longer. It’s built for people who take their paddling seriously and want a paddle that helps them go harder while feeling better—meaning more speed, more efficiency, and less fatigue.

Csillag Kocsis leading the charge for the Junior Long Distance Championship Title at the 2024 ICF Worlds in Sarasota, Florida

We worked closely with athletes and some existing customers to fine-tune every aspect of this paddle. Their input helped us create something that works for elite-level racers but is also a great fit for any paddler who wants a high-performance edge.

If you’re training hard, putting in the hours, and pushing yourself on the water, your paddle should work with you—not against you. The Hydro SynergyX isn’t just about going faster; it’s about making every stroke more efficient, reducing strain on your body, and helping you paddle longer, stronger, and with more enjoyment. Investing in a high-quality paddle isn’t just about race results—it’s about protecting your shoulders, improving your technique, and making every session on the water more rewarding.

This paddle is for those who want to unlock their full potential. Whether you’re racing, working on your endurance, or simply looking to elevate your paddling experience, the Hydro SynergyX is built to help you perform at your best. At the end of the day, the Hydro SynergyX isn’t just for pros – it’s for anyone who believes in investing in their performance, health, and enjoyment on the water.

The language around paddle design in R&D is quite “techie”. Could you explain the following tech aspects of the Hydro SynergyX in Layman’s terms for us? How do these features impact performance?

Advanced Flow Technology (AFT) is a design innovation by Black Project that enhances paddle efficiency by reducing turbulence and unwanted blade movements. This is achieved through a pronounced neck and spine on the paddle, allowing water to flow more smoothly around the blade and shaft. The result is a smoother paddle stroke, reduced fatigue, and increased speed, enabling paddlers to paddle longer and faster with less effort.

Power Scoop Technology (PST) refers to the scooped blade design with dihedral-shaped edges, which helps control water flow and improve paddle efficiency. The scoop acts like a cupped hand, holding water securely and generating power, creating a smoother, more stable stroke.

• Deeper scoops (or pockets) hold more water, generating greater power but resulting in a slower, more powerful stroke
• Moderate scoops provide a balanced mix of power and cadence, making them the ideal choice for the Hydro SynergyX and Hydro TempoX paddles
• Shallower scoops hold less water, encouraging a higher stroke rate and a more responsive feel, which is why we designed the Hydro SprintX with this style.

By incorporating dihedral edges, Power Scoop Technology distributes power evenly, preventing instability and ensuring a smooth, controlled stroke. This design works in harmony with Advanced Flow Technology (AFT) to create a stroke that is consistent, efficient, and easier on the body.

REACT+ is one of our latest innovations that enhances paddle performance by integrating two external unidirectional high-modulus carbon layers on either side of the blade. This design feature controls blade stiffness and optimizes energy return, resulting in more powerful and efficient strokes. Paddlers experience a livelier, more responsive feel, reduced fatigue, and the ability to maintain a higher cadence with less effort.

Is the Hydro SynergyX your go-to paddle?

I use all of our paddles fairly equally, depending on what I’m doing, but if I’m training alone or competing in a distance race, I tend to reach for a prototype version of the Hydro SynergyX. Even though the main development is complete, I’m always testing new iterations, construction methods, and refinements—so in a way, my paddle is never quite “finished.” I like experimenting with ideas that might come into play in future projects.

At 5’9” (175 cm) and 165 lbs (75 kg), I typically use the Medium or Small blade paired with the Tour Carbon 70 shaft. This setup gives me a good balance of power and comfort, allowing me to paddle efficiently without putting unnecessary strain on my body. While I stay in good shape, I’m not 25 anymore, so I need to be mindful of longevity and injury prevention. The right paddle choice isn’t just about performance—it’s about looking after your body so you can keep paddling for years to come.

Where do you see the future of SUP paddle design heading? Do you expect more innovation around specific performance needs?

For us, development is always driven by what paddlers need. We focus on creating the tools that help people perform better, have more fun, be more sustainable, and improve ease of use.
Two great examples of this approach in action are the Hydro SprintX and FoilX paddles, both of which were developed in response to changes in the sport:

The Hydro SprintX was inspired by APP racing in the Paris pool, where sprinting in confined water demanded a paddle that delivered maximum acceleration, stability, and efficiency in tight, explosive racing conditions. The result was a paddle designed to give athletes an edge in these high-intensity sprints. The Hydro SprintX was later used to win in the pool at the first EuroTour race this season, proving its effectiveness at the highest level.

The FoilX was developed to make it easier to get up onto foil, while also being incredibly durable—able to withstand paddle-to-foil impacts in ways that traditional paddles cannot.

This is how we approach product evolution—we listen to athletes and customers, observe how the sport is changing, and adapt our designs to meet new demands. Tom and I see a lot of potential for innovation in racing paddles, and that’s something we’ve already started with the Hydro FlowX, Hydro SprintX, and Hydro SynergyX. As new materials, data collection methods, and performance needs emerge, our paddles and fins will continue to evolve.

One of the biggest areas of development is reducing paddle weight. Right now, our racing paddles are in the 350-425 gram range, but in the near future, we expect to see 300-350 grams becoming the new standard. Lighter paddles allow for faster strokes, reduced fatigue, and improved overall performance, and we are actively exploring ways to make that a reality without sacrificing durability.

Another important factor is environmental responsibility. We are increasingly feeding sustainability into our design process. We have experimented with new materials, and while they are not yet viable for large-scale production, we believe that taking the first steps is essential. As technology advances, we’ll continue searching for ways to make paddles that are not only high-performance but also more environmentally friendly.

Materials are a key part of the future. As new materials and manufacturing techniques become available, we’re able to push paddle design further. Take, for example, our Synergy Ultimate project (oops, did I just let out a secret?!). This project introduces materials never used before in SUP paddles, resulting in even lighter weight, faster response times, increased paddling speed, and reduced fatigue. Yes, it will come at a cost—this paddle will likely be priced well over $1,000—but people want the best, and we want to push the limits of what’s possible. That mindset is at the heart of everything we do.

Find out more about the Black Project Hydro SynergyX here

To learn more about Black Project visit blackprojectsup.com

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Follow Chris Freeman on Instagram and revisit our Black Project Founder story 

*Images courtesy Black Project SUP