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Today’s #technicaltuesday we look back at the formidable task of making the 60ft hull of the current HUGO BOSS.
First of all, we keep things manageable and a 2-meter scale model of the hull is made for the purpose of testing. This all takes place is a giant indoor tank, which at 270m long is one of the largest in Europe.
Once tested, the hull shell is then created in the form of a wooden structure. This is then filled with polystyrene, creating the base layer. This is known as a female mould and is essentially the outside of the boat.
A CNC machine cuts away at the polystyrene, carving out the exact shape of the hull and removing any excess. Once finished Prepreg Carbon Fibre (already impregnated with the correct amount of resin and kept chilled so the resin doesn’t cure) is then laid into the mould in the exact orientation for the load.
The whole build bay is a giant oven, so once the layers of carbon fibre have been layered up, the hull is wrapped in a giant vacuum bag (this evenly compresses and cures the layers under the heat) and cooked at 90 degrees on a 16-hour cycle.
In the meantime the bulkheads are cured separately, then fitted after the first cook. They are laminated into position, which is a wet process and cures itself. All of this is done while the hull is still in the mould.
Finally, the deck will be fitted and the everything will be cooked again. Every cook makes the mechanical properties stronger and stronger.
When the cook is complete, the hull comes out of the mould and painting & fitting can begin!
#alexthomsonracing #sailing #thisisboss ... See MoreSee Less
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