Inside Selkirk's High-Tech Pickleball Lab

In an unassuming facility in Coeur d'Alene, Idaho, Selkirk Sport is redefining pickleball equipment through rigorous scientific innovation. The company operates a dedicated million-dollar research and development lab where aerospace-grade technology meets the court.

Here, engineers don't just manufacture paddles; they conduct experiments to understand the physics of every hit. The lab, nicknamed "Aqua," is home to specialized machinery that tests materials to their absolute limits, ensuring that every product meets the demands of a rapidly growing sport.

The heart of the lab is the "durability cannon," a machine engineers have nicknamed Mjölnir after Thor's hammer. This massive, red cage is essentially a high-tech potato cannon designed to stress-test paddles. It fires pickleballs at a stationary paddle every six seconds, repeating the impact approximately 1,000 times at speeds reaching 120 miles per hour.

Before and after the barrage, engineers use an optical profilometer—a digital microscope—to examine the paddle's surface in microscopic detail. This allows them to see every crystal of the paddle's grit and identify any defects that occur during the test.

"We can see every little crystal of our grit. We can see every dot of the ink on here. And we can see defects."

For internal inspection, the team utilizes a CT scanner. Previously, they had to saw paddles open to inspect the interior, destroying the product in the process. The scanner allows for non-destructive testing, revealing microscopic details inside the paddle while keeping it playable.

Beyond durability, the lab focuses on the physics of ball-to-paddle contact. A second room houses an "academic research cannon" or "performance cannon," which analyzes the efficiency of the collision. This data helps engineers understand how much energy is transferred during a hit.

This research is critical for game balance. As Tom Barnes explains, the sport's limited court dimensions require strict control over ball speed.

"The reason this is important is because in our sport, due to our limited court dimensions, we cannot have this ball come off too fast. We have to limit the power because if you don't limit power, the court gets really small and the game doesn't work anymore."

The lab also performs "pull tests" on material specimens, essentially ripping paddle components apart to measure resilience. Tom Barnes describes this process as applying aerospace material science to a sport that has historically been viewed as recreational.

The 22,000-square-foot "Aqua" facility is not solely for research; it also serves as a production line for finished paddles. Approximately 30 employees work at various stations, adding edge guards, caps, and grips to the paddles.

One of the most significant innovations developed here is "InfiniGrit," a spin coating applied to the popular Boomstik paddle. This coating, which retails for $333, took thousands of trials and years to develop. The name reflects its durability and lasting texture.

Quality control is rigorous. Every paddle must look perfect to pass inspection. Those that fail due to scratches or chips are classified as "seconds" and are sold as used equipment or converted into demos.

• Production capacity: ~1,000 orders daily
• Peak season volume: Up to 2,500 orders
• Facility size: 160,000-square-foot campus

Selkirk Sport was founded in 2014 by brothers Rob and Mike Barnes and their father, Jim. The brothers grew up in Coeur d'Alene, where they started their first business selling airsoft guns from their basement. They pivoted to pickleball after discovering the game in 2009, sensing its potential long before the global pandemic accelerated its popularity.

Their focus remains singular. Despite the temptation to expand into tennis, padel, or squash, the Barnes brothers refuse to diversify.

"We will only ever do pickleball. This was intentional from day one. It's called Selkirk Sport; it's not called Selkirk Sports."

The youngest brother, Tom Barnes, a former Marine, serves as the Director of R&D. He emphasizes that the company is only at the beginning of its technological journey, viewing their current capabilities as just "5% of the way there" toward their ultimate goal of innovation.

Selkirk's investment in technology has positioned them as a market leader in a sport that is rapidly evolving. By treating pickleball with the same scientific rigor as aerospace engineering, they are setting new standards for performance and durability.

Currently, the lab is working on an updated version of the durability cannon—a smaller, faster machine that will further accelerate their testing capabilities. As the sport continues to grow, Selkirk's commitment to exclusive innovation ensures they remain at the forefront of equipment design.