Hockey Stick Science: Why does my hockey stick break?

Written by: Katie Lakusta

December 6, 2023

Time to read 9 min

Every modern composite stick is measured and classified by multiple different factors— some of the most popular being flex, curve, and kick point (in some cases, lie as well). These factors allow them to be more powerful than ever before, but the trade-off is that sticks may also be more prone to breakage.

Wooden and aluminum sticks were very durable during their time, but that came at the price of increased weight and lowered performance. Composite sticks unveiled the drawbacks of these sticks in terms of performance, but that also means they must sacrifice a bit of durability to participate more in the shot. In this article, we’ll outline a bit about flex rating, some factors that can cause a stick to break, and some strategies you can try to avoid a stick break.

hockey player sitting on the bench with a Nexus Havok stick

Flex Rating

We know flex rating as a quantified number branding hockey sticks by how much they bend when you shoot. You may know that you play best with a 75 flex, or if you need to change your flex, but not everyone knows what the number actually means.

That quantity on a hockey stick’s rating is measured by how much weight in pounds will bend the stick by one inch from a neutral position. For example, that 75-flex stick should in theory bend by one inch if 75 lbs is applied to the stick. In a perfect world, this would always be the case— unfortunately, things like stick materials, the batch that the stick was made in, and the manufacturer’s own definition of flex rating can all alter the flex a bit compared to that on the stick’s label. It’s important to feel the stick a bit first before you buy.

For children and younger players, halving body weight when determining an appropriate flex rating is a good idea. Older players may need to additionally consider their style of play and how much weight they put on their stick while shooting.

Recent analysis of stick flex has demonstrated that a lower flex may actually perform better than a higher flex. Many pro players today have lowered their flex to maximize their shot potential— however, lower flex will also come with a higher risk of breakage. So, when figuring out what flex is best for you, you will ideally want to choose the lowest flex that does not break under your weight and shooting style.

The "Danger Zone"

Sticks are meant to take as much force that will bend them one inch from their original position. But beyond that, sticks may enter a “danger zone,” where they become more and more prone to damage.

Continuous use causes the stick's internal resin to constrict and harden. The accumulation of micro-damage forms a critical threshold where the stick becomes increasingly more vulnerable to fracturing. It may not break right away after the damage, but this is another way for your stick to enter the danger zone, and it could break after the next impact.

Sticks are becoming more durable as manufacturers improve their materials. However, sticks are long and meant to bend, and they may eventually break. They do break and do so often, more so if the stick cannot adapt to the power you put into them.

Trigger 7 Pro stick leaning against the wall in the dressing room

Factors That Could Influence Stick Breakage

Material Fatigue

The materials used to construct composite hockey sticks play a significant role in their durability. Different blends and weaves of carbon fibre offer a combination of strength and flexibility, with the sticks increasing in strength and performance as you go up in price point.

Over time, however, these materials can experience fatigue from repeated stress and impact; in fact, right from the initial shot, hockey sticks start to deteriorate internally. Repeated use can eventually lead to fractures or breaks— even in the best sticks. As a result, even the highest quality sticks have a limited lifespan.

First and second-price point hockey sticks will also be designed with more advanced carbon fibres and composites, making them more durable and better at resisting damage than lower-end sticks.

hockey player looking at his HZRDUS 9X stick

Impact and Misuse

As mentioned, each impact wears down the stick incrementally, whether you’re using the stick for shooting, passing, battling in the boards, etc. Using the stick outside of its intended purpose can also wear it down faster; although it’s an amazing tool for battling, it’s technically only designed for shooting. Actions like aggressive slashing, battling, or colliding with the boards can exert undue pressure on specific areas, accelerating the degradation process and increasing the risk of premature breakage.

That doesn’t mean shooting doesn’t do much damage— repeatedly using slap shots or shooting unnecessarily, can also weaken your stick’s resilience.

Manufacturing Defects

Despite strict quality control measures, the reality remains that defects can occasionally slip through during the stick production process. These defects might not be overtly visible upon purchase but can significantly compromise the stick's structural integrity, rendering it more susceptible to breakage.

Manufacturing flaws can range from imperceptible material inconsistencies to structural weaknesses that compromise the stick's durability. These anomalies weaken the stick's core, making it easier to break mid-use. Though manufacturers do strive for excellence, anomalies like air pockets, material irregularities, or lamination issues can still occur and can inadvertently compromise the stick's overall strength.

This is where stick warranties come into play— if your stick breaks due to a manufacturing defect, you can exchange it for a new one. Typically, manufacturing defects manifest themselves within the timeframe covered by the stick's warranty period. Please note that pro stock sticks are not covered by warranty.

Stick Design and Stress Points

Certain stick designs can be more susceptible to breaking. Hockey sticks designed with a low kick point tend to be more prone to breaking due to where the stick is made to flex; when you go to flex the stick, more stress is concentrated on a smaller area near the hosel, and the force can cause fractures to occur. If the concentrated stress exceeds the stick's durability, it could lead to the stick breaking. Because low kick sticks also bend more easily, they may reach their breaking point sooner, especially on hard shots or checks.

High and mid kick sticks are designed to flex nearer the middle or higher on the shaft; force in this area is distributed more widely, meaning less chance for breakage and less internal damage on the shot. Sticks with a higher flex rating will also be harder to break.

Sticks with a thinner, more flexible geometry closer to be blade or hosel may also be more prone to breakage. On the other hand, sticks with a stronger structure near the hosel can generally take more of a beating before snapping; however, sticks with a stronger hosel will be tougher and slower on the release.

Note on Pro Stock Sticks

Another option when dealing with stick breakage is to opt for a pro stock stick. Pro stock doesn’t offer a warranty, but they are cheaper, usually have a higher flex rating, and are made more durable and stiffer to complement professional hockey players’ playstyles.

Professional players focus their entire being around hockey; that would also mean that their overall strength will be higher than the average player, and they will require tougher sticks.

These sticks are specifically made for their athlete, which means they may not come in your specs, and there is also a limited quantity of them. Team sticks are also classified as pro stock. Nevertheless, these sticks are usually built more durable than other stock sticks; that toughness also translates into more and longer-lasting responsiveness.

It does come with the trade-off mentioned right at the beginning of this article though: Pro Stock also tends to be a bit stiffer than standard sticks, and the majority will range between 75 to 100+ in flex.

Strategies for Avoiding Stick Breakage

Raising Flex

It might take some time to get used to, but opting for a higher flex can make a significant difference in a stick's resilience, particularly for players prone to stick breakage.

As implied— choosing a stick with a higher flex rating inherently makes it stiffer, reducing the amount the stick flexes during shots or under pressure. This sturdier composition increases its capacity to withstand high-impact collisions with pucks, the boards, or opposing players, while additionally making the stick less prone to excessive bending.

Ultimately, it's about finding the sweet spot that both aligns with your gameplay and minimizes breakage risk. Players who frequently experience stick breakage might benefit from experimenting with a slightly higher flex stick while trying to avoid sacrificing their shooting technique. Conversely, if a stiffer stick affects shot accuracy or power, a more moderate flex might strike the right balance between durability and performance.

Adjusting Shot Technique

Sometimes, stick breakage isn't solely about the stick itself; it can also be influenced by a player’s shooting technique. Refining your shot technique can mitigate excessive stress on the stick, decreasing the likelihood of breakage.

Players with a tendency to put too much power on their shots, or incorrectly apply force on the stick might unknowingly subject it to undue stress. Balancing power and finesse in your shots can be pivotal in reducing the strain on your stick, thereby prolonging its lifespan.

Practicing proper techniques, like ensuring a balanced weight shift, utilizing your body's motion to generate power rather than relying solely on the stick, and following through after the shot, can distribute forces more evenly across the stick, reducing localized stress points that contribute to breakage. If you aren’t sure how you should change your technique, it’s a good idea to get a second opinion, ideally from a coach or other professional.

Taping Your Stick

One of our specialties at The Hockey Shop— taping your stick might seem small with more focus on the surface area and cosmetics of the stick, but having a good tape job on both the handle and the blade can do wonders for your stick’s lifespan.

The blade of a hockey stick, subject to frequent puck contact and abrasions when playing, is particularly vulnerable to chips and damage. Just the same as the shaft can be weakened through excessive use or force, so can the blade weaken through use. Tape can absorb some impact and take chip damage in place of the blade, minimizing the direct effect on the stick's structural integrity. It’s important to find a good balance between the amount of tape you use and your performance; some people prefer the feel of less tape, whereas others may like more. If your blade tends to chip a lot, however, it might be a good idea to increase the amount of tape you’re using in that area.

Beyond the blade, taping the handle can provide a layer of protection against damage from rubbing and minor scratches, while also providing some extra grip. This extra layer of defence prevents seemingly minor damage from accumulating, which could compromise the stick's overall durability.

Regularly inspecting and re-taping your stick when needed is also crucial. As the tape wears down or starts to peel, it loses its protective efficacy; make sure you’re replacing the tape from both your blade and the handle occasionally.

Consulting a Coach or Specialist

If you still aren’t entirely sure what strategies would be best for you, or what stick you should get, you can always talk with a specialist. Consulting a coach or stick specialist can provide invaluable insight into finding the appropriate flex for your playing style. They can offer guidance on the optimal flex range and help you make an informed decision that would maximize your stick’s durability while still maintaining your shot quality.

Key Takeaways for Avoiding Stick Breakage

Recognizing why hockey sticks may break is one of the best ways to prevent yours from breaking.

The flex rating indicates how much weight in pounds will bend the stick by one inch. It's essential to find a flex that maximizes your shot potential without compromising stick durability.

Sticks endure a lot but have limits. Continual use causes the stick's resin to harden, creating micro-damage that weakens the structure, eventually entering a “danger zone” where the stick becomes more vulnerable to breakage.

Sticks with a low kick point or thin, flexible geometries near the blade are more susceptible to breakage due to concentrated stress areas. Sticks with higher kick points distribute force more evenly, reducing the risk of breakage.

Material fatigue, misuse, manufacturing defects, and stick design all contribute to breakage. Repeated stress and impacts from aggressive play or using the stick in unintended ways can speed up that degradation.

Understanding these factors can help players make informed decisions about stick selection, care, and potentially decrease the risk of premature breakage. If you still aren’t sure, you can always consult a coach or stick specialist.