East Cape Marine 14m Sport Fishing Catamaran - Affinity II
Designed by Noah Thompson of Noah Thompson Designs in New Zealand, the boat was commissioned by a local Perth gentleman with a passion for fishing. The design brief called for a fuel efficient vessel of the same size and weight of his current monohull. A lengthy study of hull shapes with POD drive engine packages was conducted and a custom design, with planing hull and the Volvo IPS-400 inboard Performance System was decided on to tick all the required boxes.
The latest Noah Thompson Design power cat, built by Lloyd Powell and Kate Tarrant of The Cat Factory in Fremantle, the luxury 14m sport fishing cat, Affinity II was built from a DuFLEX / AIREX Structural Foam Kit over a 20 month period with an “out of shed” weight of 11 tonnes which, even when loaded with fuel, water, payload and passengers, was well under the original design weight.
Because of previous experience and construction success, Noah based the design for construction with ATL Composites lightweight DuFLEX panels with a structural foam core. The design was transformed into a DuFLEX Kitset and the panels were manufactured by ATL, CNC routed into kit form, including all structural and interior parts cored with a variety of densities to optimise the engineering and performance in specific areas, and shipped to The Cat Factory for construction.
DuFLEX construction significantly reduced the weight of the vessel, addressing the need to reduce fuel consumption without sacrificing comfort or performance.
Because of previous experience and construction success, Noah based the design for construction with ATL Composites lightweight DuFLEX® panels with a structural foam core. The design was transformed into a DuFLEX Kitset and the panels were manufactured by ATL, CNC routed into kit form, including all structural and interior parts cored with a variety of densities to optimise the engineering and performance in specific areas, and shipped to The Cat Factory for construction.
DuFLEX construction significantly reduced the weight of the vessel, addressing the need to reduce fuel consumption without sacrificing comfort or performance.
Additional reinforcements and taping were laminated with ATL’s high performance KINETIX® Laminating resins and all bonding, filleting and fairing were completed with WEST SYSTEM® resin and hardeners with a combination of WEST SYSTEM powder modifiers as required.
WEST SYSTEM 410 Microlight fairing compound is 30% lighter and less porous than other fairing compounds on the market and 30% easier to fair than phenolic microballoons.
“It’s not often you see a vessel with a paint job so finely detailed that you can see the ocean reflection in it. For anyone who has bogged and faired a boat will tell you it is a labour of love to get perfection.” Noah Thompson – Designer
The design layout was developed closely with the owners who had owned large boats in the past. The idea was to keep the cabins as large as possible with full head room, large doors, plenty of light, and stowage under the floor. The main cabin is open plan with the galley opening onto the aft deck for ease of cooking and serving. The lounge and adjoining seat offer a relaxing space. The owner requested that the flybridge is accessed from inside the cabin, and works well for security. Interior components were supplied as a DuFLEX / AIREX® C70.75 Kit with a 10mm foam core reinforced with a 600grm quadraxial laminate.
Palm Beach 65 Motor Yacht - Popeye
The Palm Beach Motor Yacht range was inspired by leading edge yacht racing technology. Since production began in 1995, every model has been constructed using high performance structural materials to produce extremely strong, lightweight hulls that deliver superb performance and outstanding fuel consumption.
Over the years, ATL Composites has worked with Palm Beach Motor Yachts to develop and produce CNC-routed DuFLEX® bulkhead and floor components, cored with BALTEK® SB.100 end grain balsa and laminated with a high performance epoxy resin and reinforcements to the designers specifications to optimise the weight in their various models including the Palm Beach 65.
The Palm Beach 65 is the natural progression following the popularity of the Palm Beach 50, and shares the same high quality build finishes. Smooth and easy to handle, this luxurious motor launch can be handled by family and friends without the need for extra crew.
ATL Composites have supplied DuFLEX Component Packs for the bulkheads and floors, and additional Packs have been incorporated for soles, longitudinals and selected internal fit-out pieces. Fitouts are either fibreglass-taped in place in curved areas, or bonded into position with ATL’s FRP Bonding Angles for right-angle joins.
The DuFLEX components and other fixed furniture are structurally bonded to the hull and deck with Techniglue® R15 epoxy adhesive, providing strength and stiffness to the superstructure. The R15 is a toughened system with high compressive and tensile strengths, and has been formulated to produce a high strength bond with exceptional peel properties, making it ideal for the most critical applications.
MBD 50' Harbour Racer - Atomic
Sydney businessman, Denis O’Neill wanted a super fast 50′ harbour racer, making full use of today’s technology, while paying tribute, aesthetically, to the current America’s Cup Class yachts.
Atomic was designed by Andy Dovell (Murray Burns & Dovell) with aggressive styling that incorporates the advances made in hull design in the AC Class. Atomic’s canting keel design (patent pending) has resulted in a boat that is significantly more powerful for its weight than an equivalent yacht without a canting keel. And with the addition of America’s Cup type wings on the keel bulb, it solves the need for an additional leeway- resisting surface automatically, as the keel is canted – thus introducing automatic transmission to turbo-charged yachting!
Designed to be super fast, Atomic needed to be lightweight, and also had to look super sleek. Black and red being the colour combination of choice, posed questions in choice of structural and finishing materials to obtain the optimum results. Builders, Azzura Yachts on the Gold Coast, and Andy Dovell worked with ATL Composites for the best materials for this project
DuFLEX® Composite Strips, cored with BALTEK® SB.50 80kg/m3 end grain balsa and laminated with a unidirectional E-fibreglass on either side, were manufactured by ATL Composites, and used to strip plank the hull of this custom project.
BALTEK SB.50 is genetically selected at BALTEK plantations, processed and graded to produce tightly controlled cellular density throughout. The end-grain core has consistent design properties including extremely high strength and stiffness to weight ratio. BALTEK SB.50 is the ideal core material for sandwich structures where extreme performance and weight savings are critical.
Lutra 80' Sailing Monohull - Singularity
The team at McConaghy’s has done it again with the innovative technology that was incorporated into the construction of the 80ft Mediterranean Debutante. This yacht is a sailing vessel that is setting new records at the European yacht racing events. The newly developed Lutra 80 Singularity is beautiful, sleek and incredibly fast. The whole team that was involved in the design of this magnificent sailing vessel has used cutting edge technology once only available to NASA to incorporate strength and hull integrity into their racing yach
The Lutra 80 Singularity design makes this sailing superyacht one of the finest true performance cruisers on the racing scene. An international team of experts were pulled together to create this amazing yacht. Given the fact that there are very strict guidelines that must be adhered to in the races, this craft had to be designed to not only be fast but lightweight as well. The internal fit out weight is just one and a half tons, while the overall weight is twenty four and a half tons.
The Lutra 80ft superyacht design is a very high level fit out for a racer. The full teak interior fit out is super lightweight on panels made of carbon Nomex. The canting keel is like none other this company has designed.
Farr STP 65 - Rosebud
The goal of the Storm Trysail Club and Transpacific Yacht Club was to create a boat that could compete as a Box Rule and as an IRC or ORR performer. The benefit of a Box Rule – one that limits factors such as length, minimum displacement, draft, sail area etc. – is that it maximizes performance. The STP 65 rule promotes a high-performance boat for both inshore and offshore sailing, with tight enough parameters to minimize obsolescence. The “box” sets an LOA of 20 meters (65.6ft), displacement range of 13,000Kg to 13,400 Kg, beam range 4.5m to 4.8m, a lifting keel that allows a generous racing draft of 4.8m (15’ 9”); and a healthy sail plan. The lifting keel will reduce draft to 3.3 m (10’ 10”). Displacement/length and sail area/displacement ratios are between the TP 52’s and Volvo 70’s giving promise that the boat will deliver lively performance in long distance and buoy events.
Farr Yacht Design developed the first design of the new Storm Trysail-Transpac 65 for Rosebud owner, Roger Sturgeon. The Storm Trysail-Transpac 65 (STP 65) is a high performance, light displacement, fixed keel box-rule class announced in August 2005.
In the months that followed, Farr Yacht Design worked closely with Bill Lee and others to assemble this new Box Rule. Roger Sturgeon and his project manager, Malcolm Park, were also an integral part of the rule creation and commissioned Farr Yacht Design to design their first boat of this class. Westerly Marine of Santa Ana, California, was commissioned to build Rosebud.
Rosebud, an all carbon fibre pre-preg construction, was built to strict STP-65 box rule specs. ATL Composites manufactured custom DuFLEX interior furniture components and floors that were constructed with aramid honeycomb and AIREX structural cores, laminated with carbon fibre skins. All components were QA’d to meet tight tolerances in weight and strength for the box rule spec.
Schionning Designs G-Force 1800 - Kato
“The G-Force 1800 is the ultimate in high performance cruising catamarans and is the flagship of the G-Force range. One of the main benefits of these easily driven hulls, with excellent power to weight ratio and a good WL beam to length ratio, is that you don’t need much wind to get up and go.” Jeff Schionning
Launched in May 2014, KATO, a custom Schionning G-Force 1800 is set to turn heads with stunning goods looks and outstanding sailing performance
Designed by Jeff Schionning, Schionning Designs, KATO was commissioned by a Queensland businessman, with previous catamaran experience, who wanted a performance oriented cruising catamaran with a generous pay-load, that was easy-to-handle for short-handed sailing. The design brief also called for plenty of room for storing kite surfing equipment in the cockpit and a clear area for kite launching and retrieval from the back of the boat.
Jeff specified DuraKore Strip Planking for the hulls and a DuFLEX Composite Component Pack , Techniglue epoxy adhesives and KINETIX laminating systems, for KATO’s construction, with S-Fibreglass and carbon reinforcements, where appropriate, to control weight and achieve the desired strength . The DuFLEX Panels were CNC routed into kit form and cored with a rigid end-grain balsa to optimise the engineering and performance in specific areas. The DuraKore / DuFLEX construction significantly reduced the build time while addressing the need to keep the boat as light as possible without sacrificing comfort or performance.
Built by Julian Griffiths and his experienced team at Noosa Marine, Queensland, KATO was constructed in 14 months. On her maiden voyage, in light 8 knot winds, she hit 9.8 knots of boat speed. A following outing logged 22.3 knots surfing in 2m swells with three reefs in the main and the jib, in winds ranging from 25 – 30 knots. The owner has reported that he could not be happier with the boat, and after an initial cruise to Lizard Island in the Whitsundays they are planning a world sailing adventure.
Roger Hill 19m Power Catamaran - Bajaca
With those goals in mind, it was clear to Roger that a semi-displacement hull form would meet the type of boating and performance the clients were looking for. Live aboard ability was critical so fuel capacity, water-making ability, power generation, and storage were priorities in the design.
Launched December 14 2015, the 18.7 metre Bajaca designed by Roger Hill Yacht Design, New Zealand, was commissioned by a Sunshine Coast businessman with a brief for up-to-date styling above the waterline, self-contained facilities for extended cruising in remote areas, and the ability to run at 25 knots if required.
Because of previous project experience and construction successes, Roger based the design for construction with ATL Composites DuFLEX composite panels with structural DIAB Divinycell foam cores.
The hull bottoms, lower topsides, chines and engine bearers were cored with 30mm Divinycell H130 and laminated with 2 layers of 850grm E-fibreglass quadraxial. Divinycell H has a proven track record, and its unique IPN chemical structure, yields impressive mechanical performance making it ideal for applications subject to fatigue, slamming or impact loads.
DuFLEX panels, cored with Divinycell H80 and laminated with a variety of fibreglass orientations, were manufactured for all other structural areas, predominantly in flat panel form, but in some cases, with unidirectional laminates for strip planking curved sections, to optimise the engineering and performance in specific areas.
ATL’s Featherlight panels have been supplied for the non-structural interior parts, and are cored with lower density Divinycell H60 and H35 cores laminated with a 600grm quadraxial E-Fibreglass to ensure uniform stiffness, stability and lightweight. The interior panels will be finished with a combination of timber veneers, decorative fabrics and some painted sections.
Roger commented “Construction with DuFLEX will ensure the required weight, stiffness and stability is achieved to optimise the performance and fuel consumption without sacrificing comfort or performance. Using the DIAB foam- cored DuFLEX option has saved approximately 2,000 kgs over more conventional building methods”
To take full advantage of the DuFLEX Building System, Roger worked with ATL engineers to supply the design as a CNC-routed kit to reduce labour and keep wastage to a minimum, and a DuFLEX Z-Press was supplied to Noosa Marine to join the panels and further speed up the build process.
The design layout was developed closely with the owners keeping the cabins as large as possible with full head room. The main cabin/saloon area is open plan with the doors and windows sliding away to allow entry to the cockpit with no step-over sills, and the large dining space is easily served from the galley or the BBQ on the aft platform.
The owner’s cabin is forward, featuring a large ensuite bathroom, and takes the full width of the starboard hull. The prime guest cabin also has its own ensuite and the other two secondary guest cabins share a large, mid-ship bathroom that includes a full-size domestic washing machine and separate dryer.
The design does not have a conventional flybridge, but does have a sun-bathing area on the cabin top where the tender is stored with a davit crane and a surfboard/paddleboard rack. This cabin top area is also fitted with large sliding hatches to maximise ventilations and light into the forward area of the saloon.
The boat will comfortably house family and friends, and the modern design, extensive entertaining both inside and out, luxurious interior, and a cruising speed of 16 knots will make it perfect for long range cruising and living.
Schionning Designs G-Force 2000 Speciale - KATO
The G-Force Series from Schionning Designs has continued to grow from the very first G-Force 1400 over ten years ago. Now, in 2017, another bigger sister joins the ranks.
Commissioned by an experienced G-Force owner Tony Longhurst, the 2000 Speciale is a specialised version that has some small changes and added waterline length. Overall measures are being taken to reduce weight and produce one of the lightest and fastest cruising multihulls on the water and 2000 Speciale is sure to make a splash!
With a 19.50 metre waterline length, the 2000 Speciale is the largest in the Schionning Designs G-Force range. The goal was to keep KATO as light as possible, to produce one of the lightest and fastest cruising multihulls on the water. Schionning Designs specified all structural sections of the boat in a combination of DuraKore Strip Planks and DuFLEX Composite Panels, manufactured by ATL Composites in Queensland.
Hull construction was planked with DuraKore Strip Planks, which has been the standard choice for the G-Force designs since they were first designed, however, the hulls have been reinforced with double bias carbon-fibre , rather than standard E-fibreglass, to provide extra stiffness and a reduction in weight for increased performance. All other structural components for the catamaran were supplied as CNC-routed DuFLEX Component Packs with various core thicknesses and carbon- fibre laminate specifications to meet design and engineering requirements.
Both the DuraKore Planks and the DuFLEX Composite Panels were cored with ProBalsa 150kg/m3 end grain balsa, produced by the DIAB Group, which is used extensively in the marine industry worldwide to provide exceptional compressive strength, high thermal and sound insulation and low FST (Fire, Smoke & Toxicity) properties.
The interior fit-out on KATO was also supplied as a CNC-routed Component Pack in FEATHERLIGHT Marine Grade panels from ATL. Cored with 15mm Divinycell H60, a low density unique combination of polyuren and pvc core, the Featherlight panels will provide good thermal/acoustic insulation, and being laminated with carbon fibre reinforcements, these custom panels will provide superior stiffness and ultra-lightweight in the G-Force 2000.
By specifying Components Packs for the project, weight consistency of parts was ensured, and the computer generated nesting allowed for maximum efficiency in positioning of the parts on the panels. The majority of parts were supplied with complete reinforcements applied, so the labour savings normally associated with standard wet-laminate construction, was also significant.
High performance KINETIX R246TX epoxy resin, manufactured by ATL, was specified to provide outstanding mechanical properties and stiffness when combined with the carbon fibre reinforcements in all additional laminating and taping on the cat, which will reduce fatigue and increase the overall durability and performance of the vessel. All structural bonding, filleting and fairing on the boat was completed with WEST SYSTEM 105 epoxy Resin and 206 Slow Hardener, and combined with the appropriate WEST SYSTEM powder modifier.
Roger Hill 14m Power Catamaran - Barcoo Drift
The name Barcoo Drift describes the quiet, laid back way of fishing on the Barcoo River in the North Queensland interior where the owners live and farm, many kilometers from the nearest salt water. With fishing being very high on the preferred activity, the back of the boat and cockpiit is specifically set up to optimise that activity.
The custom designed 14m sports fishing catamaran was constructed with a combination of DuFLEX Composite Panels cored with DIAB’s Divinycell H80 and HM100 structural foam cores with some panels laminated with unidirectional laminates so they could be strip-planked to conform to the more compound sections of the outer topsides and wing-deck areas. ATL Composites engineered the HM100 into the hull bottoms and lower topsides to provide extra toughness to absorb high dynamic impacts and slamming loads while ensuring a light, yet strong structure.
Designed to keep weight to a minimum and to provide a very comfortable stylish vessel for cruising the North Queensland coastline, all other structural sections including bulkheads, hull soles, cabin sides, side decks, etc, were supplied in CNC-routed Component Packs cored with Divinycell H80 in a variety of thicknesses and E-fibreglass reinforcements to meet design and engineering requirements. Divinycell H has been widely used worldwide and has a proven track record in marine sandwich composite construction.
The interior fit-out on Barcoo Drift was also supplied as a CNC-routed Component Pack in FEATHERLIGHT FF1015X6 Marine Grade panels from ATL. Cored with 15mm Divinycell H60, a low density unique combination of polyuren and PVC core, the Featherlight panels will provide good thermal/acoustic insulation and will provide superior stiffness and ultra-light weight to increase overall performance.
Noosa Marine used Techniglue R60 adhesive, in conjunction with the proprietary DuFLEX Z-Press, for the panel joining. Packed in convenient, self-mixing cartidge packs, the R60 makes mixing and application quick and mess free. A thin bead of epoxy can be applied quickly to the scarf joins on the panels and using the heated Z-Press allows the joint to be cured in approximately 12 minutes.
KINETIX R246TX / H160 epoxy systems are being used throughout the vessel for bonding, taping and additional laminating of the strip planked sections. WEST SYSTEM epoxy and powder modifiers were used fo bonding, filleting and fairing.
DuFLEX and Featherlight Component packs ensure weight consistency and build time is highly efficient. To compiment the system, ATL’s FRP Bonding Angles provide a quick and effective means for making right angle joints between the panels. These pre-cured angles reduce wet lay-up in tight corners and over-head applications, and also assist to speed up assembly.
Tony Grainger R42 Trimaran – Venom
A project that explores the boundaries between a high performance cruiser and a lightweight racer, the R42 deploys a fine main hull with just enough concession to creature comforts below decks to ensure that planning a long term cruise, is as equally realistic as mixing with the action at the front end of the fleet in a major race series.
The R42 is custom designed to a well thought through design brief from an experienced Australian trimaran owner.
Engineered by Composites Consulting Group (CCG) to Category A Offshore, the R42 designed by Tony Grainger, is the latest high performance trimaran under construction at Australian Custom Multihull Yachts at The Boatworks on Queensland’s Gold Coast.
The mould frames and strongbacks are made from 16mm MDF that were CNC machined by ATL Composites from electronic cutting files. The cutting files provide slots for fast assembly and the building forms are stabilised by locking the joints with epoxy fillets. The beams are symmetrical about the athwartships axis, so one set of female tools can be used to build all of the beams. The primary beam is a box structure that sits inside the fairings. The fairings are non-structural, so the laminates are quite light.
The main hull planking material is made with DuFLEX Composite Panels with a 15mm Divinycell H80 structural IPN foam core with 200grm carbon unidirectional laminate on each face. The DuFLEX panels are manufactured under heat and positive pressure by ATL Composites to ensure a consistent laminate with a high fibre ratio. The panels were supplied in 1200mm x 2400mm sheets with the proprietary DuFLEX Z-joint on each 1200mm end.
The panels are bonded with Techniglue R60 structural adhesive, supplied in cartridge packs, using ATL’s Z-Press which applies pressure and heat to the join, allowing the epoxy to cure in just a few minutes. The panels are progressively moved along until a panel of the full length of the hull is created. The full length panels were then ripped into strips of varying widths and planked over the temporary frames to make the hull shell.
The planking has been reinforced with a combination of carbon fibre double bias reinforcements laminated with the high performance KINETIX R246TX Thixotropic Laminating epoxy under vacuum to achieve a high fibre to resin content to optimise the construction for weight and stiffness.
In the more compound sections of the main hull, Divinycell H80 foam in a variety of thicknesses has been used to create the shapes, while H100 and H200 was used intermittently in specific high load areas, and then laminated in-situ with R246TX and a combination of KINETIX H160 Medium and H126 Super Fast Laminating hardeners
The hull has been faired with Technifill XP R1160, a lightweight, pre-thickened compound that is easy to sand with no shrinkage.
More photos of this project can be viewed on https://www.graingerdesigns.net/trimaran-designs/r42-trimaran/r42-build-gallery/