Early manufacturers used wood, gut and rubber to build tennis rackets. In 2011, tennis rackets are usually made from graphite, carbon fiber or aluminum, depending on the price and player level. The manufacturing process with tennis rackets involves roughly three stages: frame construction, stringing and finishing. Within these three steps, different manufacturers add slightly different techniques and processes to make strong, reliable rackets.
Frames
For most aluminum-frame rackets, the metal is heated until melted and easily workable as a molten liquid. While the aluminum is hot, manufacturers pour the liquid into a die cast that forms the basic frame shape and allows it to cool. Composite rackets consist of a fibrous substance such as graphite or fiberglass. The fibers are wrapped together and combined with a hardening agent called epoxy resin, according to the International Tennis Federation. The substances are heated and pressurized in a mold cast to create the frame shape and left to harden.
Strings
Modern rackets usually feature taut nylon strings as opposed to the natural gut used in early models. The process of stringing follows a similar path, whether the racket is made from aluminum, titanium or graphite. In all cases, rackets are clamped and holes carefully drilled at regular points around the racket rim. A grommet strip -- a plastic strip with serrated divisions along the edge -- lines the racket rim. The nylon string is then pushed through each drilled hole and pulled taut. This could be either a manual or mechanical process, depending on the manufacturer.
Finishing
Tennis rackets have soft grip tape wrapped around the handle to help prevent slipping in a player's hand. According to Tennis 101, most grips range from 4 to 4 5/8 inches. Most racket handles are hollow to reduce weight, so a butt cap is inserted into the end to seal off the hollow interior. When the racket is strung, tape wraps around the handle. Brand names usually paint their logos onto the head or handle of the racket toward the end of the manufacturing process.
Considerations
Aluminum rackets will also go through the process of tempering -- with the metal heated then cooled suddenly in water to harden the material. Dipping the aluminum in sulfuric acid and passing electricity through the metal also helps create a shiny, tougher finish. A similar process works with titanium rackets. Manufacturers frequently add new tweaks and engineering changes to the basic tennis racket design. For example, additions include shock absorbers in the handle, rim or between the strings.
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