Design innovations and new directions in technology.

Most boatbuilding facilities that have all gone through incremental and sometimes revolutionary changes in the four key areas of boat building: moulding, trimming, assembly and finishing.

Most boatbuilders are constantly tweaking and revising the process to include the use of robotics, template designs and rapid prototyping thus speeding up the production process. A highly skilled and mobile workforce ensures high-end finishing with up to three separate quality control checks before the boat leaves the factory.

New composite techniques can save up to 50% in costs when applied to new models.

GRP MOULDING

The construction process gets underway in the moulding department where a female mould is sprayed with gel coat resin. This is followed by a hand lay up of fiberglass, more cloth and more resin.  GRP Custom Mouldings can be very tricky.

All fibreglass used in the mould room is pre-cut, labeled, and delivered to mould room team for building of boat hulls, boat decks, and grids. The delivery of fibreglass kits ready for use assures precise fitting and correct quantities. With each layer of fibreglass a coat of resin is applied, and the process of hand rolling the fibreglass layers begins. Each layer of glass is carefully rolled by use of small grooved rollers, which will remove trapped air and excess resin. Once this process is completed, then the next layer of fiberglass can be applied.

Overhead receivers are used for securing the yacht bulkheads as well as locations for hatches and access areas for deck mounted hardware. The overhead liner also provides locations for conduits for running of electrical wiring as well as for instrumentation wiring.

Vacuum Bag-Infusion with Vinylester Resin

This technology is less than 10 years old and is revolutionizing the construction of modern yachts. After comparative laboratory trials, this technique provided excellent engineering results. These results are equal to or superior to pre-preg in as much as fabric compaction is achieved without the slightest possibility of air being captured in the composite.

The fabric is positioned with the same precision used in pre-preg. This technology also allows the boatbuilder to construct simultaneously the outer skin, core and inner skin, as well as the structure (in case of female mould construction). Using glue between each layer is unnecessary. For each hull made, a sample can be saved for engineering or chemical testing. The Tg obtained is at least 80°C (110°C in vinylester).

TRIMMING MOULDINGS

Some cleaning and adjustments are made in this facility. The windows, ports, hatches, lockers and other openings are cutout and cleaned. Any voids, low spots or imperfections are ground out and repaired at a central inspection station. From here the bridgedeck is moved to the assembly line where the modular interiors are attached.

Pre-assemly Prepping booths house boat hulls prior to delivery to the assembly line and help streamline the process and maintain high organizational levels in the process.

ASSEMBLY

All the pieces of the puzzle start to fit together in the assembly bay. These include the installation of pre-cut wood interiors made in the wood shop.

The "moving" assembly lines are characteristic of many factories. This method of bringing the pieces to the stations where workers and their tools are located is extremely efficient in reducing the wasted man-hours that occurs when the moving assembly line is not employed.

Raised assembly lines and mezzanines are other design features that are not seen in many major sailboat manufacturing facilities. This design feature affords a safer platform and easier access in and out of the yachts. These rolling assembly lines allow yachts to move from station to station. The tools and craftsmen remain in place.

Bulkhead Installation

The bulkheads are installed and bonded to the hull (and later to the deck) for stiffness, and all wiring is placed in the pre-designed raceways port and starboard. The engines, tanks, hoses, thru-hulls, cabinets, windows, ports, and hatches are all installed on this line.

After the entire interior is assembled, the deck is then set onto the hull using the same poly-sulfide adhesive and sealant along with bolts for a strong, waterproof bond. The boat bulkheads are bonded on all 360 degrees to the boat hull and deck surfaces.

The yacht deck hardware, including the winches, hatches, sheet stoppers, blocks, cleats and toe-rail are attached. Each piece of deck hardware is installed by teams of two, with one on deck and the other below bedding and tightening each nut and bolt.

A Touch of Wood

Interior furniture kits are completely finished with varnish and ready for assembly.
Computer controlled cutting and finishing machines produce interior furniture which is pre-fitted in a duplicate mould of the hull grid mould, prior to final installation in the yacht. This extra step allows a precise fit of all interior furniture and ensures efficiency of assembly outside the hull.

Ultrasound machines are used to cure the resin on laminated wood that are fused together in three layers. Greater speeds were introduced with the inclusion of CNC routing machines that work off coded templates and quickly punch out grooved interior wood finishing.
Furniture is protected with clear plastic sheeting and foam held in place by tape.

EXPEDITION OR FINISHING

The completed hull is then lifted into one of the huge in-house test tanks. The engine and electronics are tested as well as all the through-hulls for any leaks. The finished boats then go to a final inspection stage where a team goes over the entire hull, deck, interior and exterior checking each system for integrity and quality. Any boat that shows anything that is below the standard gets repaired before it goes out to the shipping area.

Yachts are also fitted with floorboards, cushions, and loose gear is stowed in sail lockers. Final quality checks are preformed and the yacht is released to the shipping department.

Moulding.

Wherever possible technology is used to aid, streamline and improve the process but there is a high degree of human interaction to enforce quality control and improve production line speeds.

The combined advances in moulding, trimming, assembly and expedition are being used by many of the top boatbuilders.