Rugby Ball

1. Design & Material Selection

• Regulatory Compliance: Follows World Rugby specifications for size (size 5 for adults: 28–30 cm long, 58–62 cm circumference) and weight (410–460 grams).

• Outer Casing:

  • Traditional: Leather (treated for water resistance) for premium match balls.

  • Modern: Synthetic materials (polyurethane, PVC, or thermoplastic polyurethane) for durability, all-weather grip, and cost efficiency.

• Bladder: Latex or butyl rubber for air retention and pressure consistency.

• Lining: Layers of polyester or cotton fabric between the casing and bladder to maintain shape.

2. Panel Cutting

• Four-Panel Design: Die-cut synthetic or leather sheets into four identical oval panels.

• Surface Texture: Embossed or molded with pebbling/chevron patterns to enhance grip.

• Reinforcements: Edges are reinforced with adhesive or fabric strips for durability.

3. Bladder Production

• Latex/Butyl Molding: Bladders are molded into a rugby ball shape and cured.

• Valve Installation: A one-way air valve is inserted for inflation.

4. Panel Assembly

1. Lining Application: Fabric layers are glued or laminated to the inner side of each panel.

2. Panel Stitching/Bonding:

   • Hand-Stitching (Premium Balls): Panels are sewn together with waxed polyester thread, creating raised seams for better grip.

   • Thermal Bonding (Recreational Balls): Panels are fused using heat and adhesive for seamless construction.

3. Bladder Insertion: The bladder is placed inside the stitched casing.

5. Inflation & Shaping

• Pre-Inflation: The ball is partially inflated to stretch the casing and align panels.

• Final Shaping: Inflated to regulation pressure (9.5–10 psi) and heat-treated to set the shape.

6. Quality Control

• Pressure Test: Check for air leakage over 24–48 hours.

• Weight & Size: Verify compliance with World Rugby standards.

• Durability Testing: Simulate kicks, passes, and scrums to test seam strength and wear resistance.

• Aerodynamics: Wind tunnel testing for flight stability.

7. Branding & Finishing

• Printing: Logos, certifications, and design elements are screen-printed or heat-transferred.

• Surface Treatment: Apply coatings for UV/water resistance or enhanced grip.

8. Packaging

• Deflated, folded, and boxed with care instructions.

• Match balls may include a pump and carry bag.