How Are Volleyballs Made? Materials and Manufacturing Explained

Buying the wrong ball leads to flat bounces and sore arms. Most people don't realise that poor construction causes air leaks and peeling panels after just a few sessions. We've put this guide together to explain the volleyball manufacturing process so you can understand how volleyballs are made and what they’re made of.

Key Takeaways

• High-quality volleyballs rely on an internal butyl rubber bladder that is pressure-tested for 24 hours to ensure elite air retention and a consistent bounce.
• Laminated balls offer a premium feel while machine-stitched versions provide a robust and affordable solution for schools.
• Performance is dictated by the outer material where PU is the softest choice for match play while TPU and PVC provide 100% synthetic durability.

What Are Volleyballs Made Of?

Every quality volleyball is built using four main layers that work together for bounce and comfort. The most important part is the outer cover because it's the part you actually touch.

• Outer Cover: This is usually made from PU, TPU, or PVC. PU is the premium choice for match play because it's soft and responsive.
• Panels: These are the individual sections of the cover. Most standard balls have 18 panels, though some modern designs use fewer.
• Inner Lining: Layers of cloth or polyester are wrapped around the bladder to help the ball keep its round shape.
• Volleyball Bladder: This is the internal balloon that holds the air. It's the engine of the ball that provides the bounce.

How Are Volleyballs Made? A Step-by-Step Overview

The volleyball manufacturing process is a mix of high-tech machinery and careful assembly. It starts from the inside out to ensure the ball is perfectly balanced.

1. Creating the Bladder: Manufacturers mould the bladder into a sphere. This is the foundation of the entire ball.
2. Adding the Lining: We wrap the bladder in layers of nylon or polyester thread. This step is vital because it prevents the ball from becoming lumpy when inflated.
3. Panel Preparation: Outer volleyball materials are cut into precise shapes. Depending on the quality, these are either prepared for stitching or coated with adhesive for bonding.
4. Cover Attachment: This is where the panels are joined together over the inner lining. This is the stage where a ball becomes either a stitched or a laminated product.
5. Quality Control: Every ball is inflated and left for 24 hours to check for leaks. We also test the roundness and weight to ensure it meets official standards.

Stitched vs Bonded Volleyballs

Laminated or bonded balls are generally considered good to best quality. In this process, the panels are glued to the inner lining to leave a smooth surface with no visible seams. This makes for a very consistent flight and a professional feel. These are the standard for high-level match play.

Machine-stitched volleyballs are usually for basic training or recreational use. You can see the thread between the panels. These are great for schools because they're robust and affordable, but they don't feel quite as true as a bonded match ball. Stitched balls are almost always made from PVC because the material is tough enough to hold the thread.

The Role of the Volleyball Bladder

Your choice of volleyball bladder changes how often you'll need to reach for the pump. Most balls use either Butyl or Latex. Butyl bladders are the gold standard for air retention. They can hold air for weeks or months without needing a top-up. This is why they're the top choice for schools and clubs. Latex bladders feel much softer and have a more responsive bounce, but they're porous. This means they lose air slowly and usually need to be pumped up before every single game.

Training vs Match Volleyballs: PU, TPU, and PVC

Choosing between a training vs match volleyball comes down to the specific materials used. Each offers a different balance of feel, cost, and durability.

PU (Polyurethane): This is the high-end match material. It's soft on the arms and mimics the feel of genuine leather. It's more expensive but also more environmentally friendly than other plastics. This is what you want for competitive games.

TPU (Thermoplastic Polyurethane): This is a medium-grade material usually found on training balls. It's a plastic that feels similar to PU but isn't quite as soft. It's incredibly robust and great for daily practice where the ball takes a lot of punishment.

PVC (Polyvinyl Chloride): This is the budget-friendly choice for basic training. PVC is a tough plastic that handles rough grounds and high-wear areas well. While it doesn't feel as premium as PU, a good quality PVC ball is perfect for schoolyards and beginners.

Indoor vs Outdoor Volleyball Construction

The indoor vs outdoor volleyball construction depends heavily on moisture and surface friction. Indoor balls are designed for climate-controlled gyms. Their covers are soft to give players better grip and control during fast rallies.

Outdoor or beach volleyballs are built to survive the elements. They often have stitched panels to handle sand and grit. The materials are water-resistant so they don't get heavy if they touch damp grass. They're usually a bit heavier to help them stay on course if there's a breeze.

Why Do Volleyballs Feel Different?

If you've ever switched from a cheap playground ball to a professional match ball, you'll notice a massive difference in sting. Why do volleyballs feel different? It mostly comes down to the cover material and the padding underneath.

• PU Covers: These feel cushioned. They're designed to absorb the impact on your forearms so you can play longer without bruising.
• PVC Covers: These feel harder. While they're great for durability, they can be a bit tough on beginners' arms.
• Inflation Levels: Even a premium ball will feel like a rock if it's over-inflated. Always check the recommended PSI printed near the valve.

Find the Best Volleyball at SUMMIT Sport

The SUMMIT Sport volleyball range is based on real-world performance. For junior players and school PE, we often recommend our PVC stitched balls because they're cost-effective and handle rough treatment. For clubs and serious players, our PU laminated match balls provide the soft touch and consistent bounce needed for competitive play.

Also, we look for materials that match the Australian environment. Whether you need a ball that survives the hot sun on a backyard grass court or a professional ball for a tournament, we've got a construction type that fits.

Need more advice? Grow your leadership skills with our Guide to Coaching Volleyball. Plus, ensure your players develop perfect technique and avoid injury with our volleyball size guide.