HiBoard™

A Modern, Non-Phenolic Alternative to Traditional Pickup Flatwork

HiBoard™ is a modern, plant-fiber-based electrical insulation material created specifically for guitar and bass pickup flatwork. Engineered as a non-phenolic alternative to traditional paper-resin laminates commonly referred to as Forbon, HiBoard™ delivers comparable mechanical and electrical performance while significantly reducing the environmental and occupational hazards associated with phenolic materials.

Manufactured from renewable hibiscus fiber and formed using resin-free, low-toxicity bonding processes, HiBoard™ avoids phenol-formaldehyde systems and the VOC emissions, hazardous dust, and sharp chemical odors they introduce.

Available in black, grey, and red, HiBoard™ is designed for today’s builders, manufacturers, and educators who want safer materials without compromising precision, consistency, or tone.

A Safer, Smarter Approach to Pickup Flatwork

HiBoard™ is a next-generation, plant-fiber insulation material developed for pickup builders who value tonal consistency, workshop safety, and responsible material choices—without compromise.

Inspired by traditional non-resin fiber insulation materials and refined with modern process controls, HiBoard™ is engineered for precision CNC machining, laser cutting, and hand fabrication.

The result is a flatwork material that delivers the performance builders expect, while minimizing the health, environmental, and disposal concerns associated with phenolic laminates.

The Limitations of Traditional Flatwork Materials

For decades, the industry standard for pickup flatwork and electrical insulation has been phenolic paper laminate (commonly known as Forbon). While effective in many applications, phenolic materials rely on synthetic resin systems derived from phenol and formaldehyde.

These thermoset resins introduce challenges that are increasingly difficult to justify in modern workshops, including hazardous dust, chemical off-gassing, limited recyclability, and higher environmental impact.

HiBoard™ preserves the functional strengths of traditional flatwork materials—while intentionally avoiding the tradeoffs inherent to phenolic resin systems

Raw Materials & Manufacturing — Comparison Chart

Factor	HiBoard™	Forbon (Phenolic)
Feedstock Source	Renewable plant fiber	Fossil fuel / petrochemical
Hazardous Chemistry	Non-phenolic, low-toxicity system	Phenol + formaldehyde resin
Manufacturing Energy Intensity	Lower-temp processing	High-temp cure under pressure
VOC / Hazardous Byproducts	Minimal hazardous waste	VOC + hazardous waste risk
Embodied Carbon (Relative)	Lower embodied carbon	Higher due to petrochemicals

Note: Percent bars are relative indicators to communicate directionality (not an LCA claim).

Source to Sheet — Material Lifecycle Comparison

Lifecycle Stage	HiBoard™	Forbon (Phenolic)
Raw Material Extraction	Renewable plant fiber cultivation	Oil & gas extraction
Chemical Inputs	Non-phenolic, low-toxicity binder system	Phenol + formaldehyde resins
Processing & Curing	Lower-temperature processing	High-temperature cure under pressure
Energy Intensity (Relative)	Reduced energy input	Energy-intensive resin curing
Emissions & Waste	Minimal hazardous waste	VOC + hazardous waste generation
Cradle-to-Gate Carbon Impact	Lower embodied carbon (relative)	Higher due to petrochemical inputs

Note: Bars represent relative comparisons from source material through finished sheet (cradle-to-gate) and do not constitute a formal life-cycle assessment (LCA).

Builder Safety & Workshop Health — Comparison Chart

Factor	HiBoard™	Forbon (Phenolic)
Dust Hazard (Cutting / Sanding)	Lower-toxicity, wood-like dust profile	Phenolic dust (irritant / hazardous)
Fume Risk (Laser / Heat)	Better suited for laser + shop use (with ventilation)	Not recommended without industrial filtration
PPE Burden	Standard dust control + common PPE	Higher PPE demands + strict dust control
Shop Air Quality (Small Spaces)	Better suited for garages / classrooms	Harder to manage safely without extraction
Skin / Handling Irritation (Relative)	Lower irritation risk during handling	Higher irritation risk from dust/contact
Education / Makerspace Suitability	Aligned with classroom safety expectations	Often restricted due to dust/fume concerns

Note: Bars are relative comparisons intended to communicate practical shop implications. Always use appropriate dust collection and ventilation for any machining operation.

HiBoard™ FAQ

Short, engineer-safe answers you can publish without overclaiming.

Is HiBoard™ “phenolic” or “Forbon”?

No. HiBoard™ is a non-phenolic fiber insulation material engineered for pickup flatwork. It is designed to avoid phenol-formaldehyde resin systems commonly used in phenolic paper laminates (often referred to as Forbon).

Is HiBoard™ “all natural” or chemical-free?

HiBoard™ is plant-fiber based, but like all engineered materials it uses controlled processing aids and bonding chemistry. We avoid phenol-formaldehyde resin systems and focus on non-phenolic, low-toxicity processes.

How is this different from traditional “steel paper” / vulcanized fiber?

Traditional non-resin fiber materials can be highly aligned with environmental goals, but grades vary widely. Some are resin-modified (including phenolic impregnation), which changes safety and disposal characteristics. HiBoard™ is intentionally positioned in the non-phenolic category with modern consistency controls for pickup manufacturing.

Is HiBoard™ safe to laser cut?

HiBoard™ is better suited for laser cutting than phenolic laminates, but any laser cutting requires ventilation and fume extraction. Always use proper airflow, filtration, and follow your laser manufacturer’s safety guidance.

Does HiBoard™ create hazardous dust when CNC machining?

HiBoard™ is designed to reduce the hazards associated with phenolic dust. That said, all machining produces particulates—use dust collection, respiratory protection as appropriate, and follow shop safety best practices.

Will HiBoard™ affect tone?

Flatwork primarily contributes through dimensional stability, coil geometry, and electrical insulation. HiBoard™ is engineered to support consistent coil builds and reliable insulation. If you’re doing controlled A/B testing, we recommend keeping all other variables constant (wire, tension, magnets, charge, potting, baseplate, cover, etc.).

What thicknesses and colors are available?

HiBoard™ is offered in multiple standard thicknesses and is available in black, grey, and red. If you need a specific thickness or tolerance window for production, contact us and we’ll confirm what’s available.

Is HiBoard™ recyclable or biodegradable?

HiBoard™ has a more favorable end-of-life profile than thermoset phenolic laminates, but real-world recyclability depends on local facilities and how the material is used. We avoid broad “recyclable everywhere” claims and focus on measurable reductions in phenolic chemistry and associated hazards.

Is HiBoard™ intended to replace every phenolic application?

No. HiBoard™ is engineered specifically for pickup flatwork and related guitar/bass insulation uses. If you have a higher-heat or specialized industrial application, we’re happy to review requirements and advise whether HiBoard™ is a fit.

Do you provide an SDS and technical data?

Yes. We can share an SDS and available technical information (typical thickness tolerance, density range, and handling guidance). For OEM evaluation, we can also discuss batch consistency and machining recommendations.