The Fusion 40 "Kit Cat" is revolutionising the boatbuilding industry. This vessel has been designed from the beginning as a high performance cruising catamaran that can be stacked into 40 foot containers and freighted anywhere in the world.
This photograph shows the infusion moulded components as they would appear when removed from the container. Complete with moulded non skid and all the recesses for hatches and portlights. The components even have individual quality control certificates. |
By producing this modern catamaran in modules, which in turn fit in containers, it has meant delivery is simple and it has opened the doors to worldwide marketing of the Fusion 40. The cost savings on overseas shipping as deck cargo, is in excess of $40,000.00. Private contractors are available to assist with assemblies to any stage if you desire.
By producing a catamaran in sections also has great appeal to the professional boatbuilder as well as amateurs, as they can install mechanical and furniture items as they assemble, rather than working in confined spaces. | |
No longer are you dictated to, Fusion Catamaran Co. supplies the structural components along with the hull and deck sections but leaves the entire fitout and layout to the owner. This allows the builder to work with their preferred materials, and allows for personal preferences as to accommodation and functions. However Fusion Catamarans have a very comprehensive Multihull Construction Guide web site to support clients. | |
By producing the supplied components in Foam/Glass, they are weather proof and even if your build project ran into years, there will be no deterioration, shrinkage, dry rot, etc., of the components | |
Instead of spending 6 months gluing strips and planks, then glassing over and fairing, fairing, fairing only to finish up with a product that has small appeal to another buyer, you can now have a beautifully gelcoated, factory finish on your Catamaran, which can be assembled in as little as 12 days (4 men). | |
Having gelcoated, fibreglass, foam cored and production built components (to Class "A" CE Certification) provides comfort to the owners that his vessel will be highly sought after when it comes time to sell. | |
Also by having a worldwide marketing base through the Agent/Builder network, an owner can gain comfort in the fact that anywhere he travels he can be assured of a helping hand as well as recognition of his Fusion. | |
Whilst these pictures above were taken during the assembly of the test boat in Fusion's facility, the pictures at the below show assembly can be achieved in more simple surroundings. | |
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For more information on this fabulous product, or even where the closest one to you is, please click here to contact us .
Of sustainable innovative solar yachting.
Sunreef Yachts is the world’s leading designer and manufacturer of luxury sailing and power multihulls.
Each catamaran, motor yacht, and superyacht built is a bespoke creation. Every yacht is a vision brought to life, thoughtfully designed to deliver luxury, style and comfort.
Sailing yachts, power yachts, superyachts, with a 360° approach.
to eco cruising, they offer cutting-edge electric propulsion , naturally-sourced sustainable materials, smart energy management and new technologies including a patent-pending solar skin produced in-house.
Renewable energy on yachts, energy efficiency on yachts, sustainable finishing materials.
Equipped with the world’s first and only composite-integrated solar panel system and using the industry’s lightest batteries, the Sunreef Yachts Eco catamarans provide the best of autonomy and energy efficiency for environmentally-conscious luxury cruising.
The Sunreef Yachts Eco harvest power from the sun more efficiently than most solar catamarans. First in the world In-house pattented designed and manufactured by the shipyard, Sunreef Yachts’ solar panels are fully-integrated with the composite bodywork, vastly increasing the amount of solar power generated.
Fernando alonso.
brand ambassador since: September 2021
Two-time Formula 1® World Champion Fernando Alonso commissioned a custom 60 Sunreef Power Eco catamaran with Sunreef Yachts.
brand ambassador since: June 2022
An unstoppable and passionate adventurer, Mike Horn has accomplished a series of groundbreaking expeditions including a legendary solo journey around the equator without motorized transport
Hailing from Belgium, Manutti is a renowned outdoor luxury furniture brand founded by CEO Stephan
Sunreef Yachts, the world’s leading luxury catamaran shipyard, proudly announces the 100 S
A New Partnership begins Sunreef Yachts Eco joins Rafael Nadal’s E1 team as Official Partner. T
Sunreef Yachts Eco celebrated a spectacular victory at the International Yacht & Aviation Awa
Sunreef Yachts is proud to announce a new partnership with IYC, appointing them as the Exclusive
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Power Catamarans have been growing leaps and bounds in popularity, and, in lengths and widths. And for good reason. These cruise-centric yachts offer homelike livability for avid travelers, are fuel efficient and are fairly intuitive to run. Power cats are popular in the bareboat charter market too, for these very reasons.
Here, we take a look at 12 catamarans ranging from a cruising-couple-size 36-footer to a 78-footer for friends, family and some more friends. And there are myriad power options: outboards, diesel inboards, hybrid or even all-solar power.
The Fountaine Pajot MY44 , a creation of Italian architect Pierangelo Andreani and French designer Daniel Andrieu, has a main deck that’s open from the aft-deck seating all the way forward to the starboard helm station. The sense of spaciousness is significant, for several reasons. First, four glass panels aft can all slide to port, creating an indoor-outdoor space with the aft deck and salon. In the salon, 32-inch-high windows extend for 12 feet down the sides of the yacht, with three sections per side, bringing in natural light along with the three forward panes that comprise the windshield. Finally, 6-foot-6-inch headroom provides vertical clearance, with a 21-foot-7-inch beam that adds interior roominess while keeping the yacht stable.
Read more: Fountaine Pajot MY44
The ideas about which solar panels, electric motors, inverters and the like to use — and more importantly, Michael Köhler says, how to configure them — became the basis for the brand Silent-Yachts. The company offers 55-, 64- and 79-foot catamarans that run on solar-electric propulsion. The Silent 55 premiered this fall, and the 64 is sold out for the next two years, Köhler says.
Read more: Silent 55
As founder and director of The Powercat Company, a Horizon Power Catamarans distributor, Stuart Hegerstrom had long believed that catamaran builders needed to design their yachts to more stylish standards.
“The boats were very boxy,” he says, based on his years of experience with cats in the charter market. He and his partner, Richard Ford, asked Horizon to produce models that had high-end finishes and looked good inside and out.
The Horizon team brought in mega-yacht designer JC Espinosa to work with its own craftsmen. The result aboard the Horizon PC74 is a catamaran with exterior styling, layout and functionality that should appeal to private and charter owners alike.
Read more: Horizon PC74
The Aquila 36 is a departure from her sisterships in that she is an outboard-powered, express-cruiser-style catamaran, but she also adheres to MarineMax’s philosophies.
With a single main living level from bow to stern and a beam of 14 feet 7 inches, the Aquila 36 is like a bowrider on steroids. She has seating that can handle 20 adults for outings and barbecues, and there are two staterooms below, one in each hull, for family weekending. The staterooms have nearly queen-size berths, en suite heads, stowage and 6-foot-6-inch headroom.
Read more: Aquila 36
Lagoon is a division of Groupe Beneteau, the world’s largest builder of sailing yachts, and the Lagoon Seventy 8 Powercat is a developmental sistership of its Seventy 7 super sailing cat. The Seventy series yachts are built at Construction Navale Bordeaux in France, which had to add a new yard to construct these catamarans because they require separate stern molds for the power and sail versions.
Read more: Lagoon Seventy 8 Powercat
To understand the Horizon PC60 power catamaran , you need to put aside preconceived notions about midsize yacht amenities. For example, main-deck master suites are the province of yachts over 100 feet length overall. Incorrect. This 60-footer has an elegant and spacious owner’s stateroom on the same level as the salon. If you want a 14-foot center console tender on a 60-foot yacht, you have to tow it. Wrong again. On the PC60, you hoist it onto the upper deck, no problem.
Read more: Horizon PC60
Sunreef is known for pushing the boundaries of catamaran design, incorporating four adjustable hydrofoils into a twin-hulled speedboat.
The Polish builder is one of several European builders (including Evo, Fjord, Wider and Wally) transforming the open day-boat category with creative designs. Beyond its hydrofoils, the 40 Open Sunreef Power ‘s cockpit has side “wings” along the aft gunwales that fold out at anchor, widening the beam from 17 feet to 22 feet 9 inches.
Read more: 40 Open Sunreef Power
Sunreef Yachts introduced its 50 Amber Limited Edition , with plans to launch just 10 hulls of the exclusive design.
The Sunreef 50 Amber Limited Edition will have a carbon fiber mast and boom, four layout options and numerous amber-colored elements, including the hull.
Read more: Sunreef 50 Amber Limited Edition
Fitted with the optional twin 300-horsepower Volvo Penta D4 diesels, the Lagoon 630 MY burns only 1.64 gph total at 6 knots, giving a theoretical range of 2,952 nautical miles with standard tankage of 793 gallons. Hull No. 1 had an optional 502-gallon tank, giving it transatlantic range.
Luxury, stability and economy are all hallmarks of Lagoon’s return to luxury motor yachts. If you can take a ride, it will be worth your time.
Read more: Lagoon 630 Motor Yacht
The Fountaine Pajot MY 37 easily accommodates the seafaring family with three- and four-stateroom options. In the three-cabin version, called Maestro, you’ll find an owner’s suite in the portside hull with a queen-size berth and en suite head. Two double-berth cabins and one more head are available for the kids. If your brood is bigger, the Quator setup features four double cabins with two heads.
The 37 is a traveler and can be powered with twin 150 hp or 220 hp Volvo Penta diesels. Top speed with the smaller engines is 17 knots, while it’s 20 knots with the bigger power plants. Interestingly, at 7 knots, the fuel consumption is the same, with either set of motors offering voyagers a 1 ,000-nm range.
Read more: Fountaine Pajot MY 37
Many yachts boast eco chops because they have a handful of solar panels that power the microwave or navigation lights. The Solarwave 64 , launched last summer, has the potential to run on sunshine alone. The vessel’s 42 solar panels generate 15 kW that are stored in batteries weighing about 1,300 pounds. They connect to electric motors.
Read more: Solarwave 64
This British builder says it strives for design innovation and the Glider SS18 displays that DNA, the result of 8 years of research and development. She has a head-turning, catamaran hull form constructed from aluminum and composite materials. She is 60 feet LOA with a 17-foot beam, and has a relatively shallow 1-foot draft. Powered by quad Yamaha 300 hp outboards, she can reportedly reach 50 knots, and with her Stability Control System (SCS), should give a smooth ride while doing it.
Read more: Glider SS18
Recommended equipment.
The schionning team have a lot of contact with equipment suppliers and manufacturers, and hear feedback on certain brands or systems from our many customers. there are many schionnings cruising the world and testing products longevity and the customer service offered by the manufacturer., on this page we will list products and companies that we know to provide above average quality and service. it is always growing, and if your company provides equipment used on our designs and you would like to be included - please contact us., engines & drive systems.
Visit: https://oceanvolt.com
Back in 2013 I knew that my boat batteries were reaching the end of their lives, I had been researching LiFePO4 cells for a few years and decided that I should install them. Unfortunatly I was unable to find a local supplier. So Lithium Power was established.
The technical information page is a collection of documents (mostly in pdf format) on the materials and systems used in schionning catamarans. including data sheets, engineering information, strength comparisons of each core material and informative articles from jeff outling the design of certain system such as engine choices and main sheet systems., detailed engineering data for your research, we understand that getting your head around the process of building your own boat, or having one built, can take a little while. to gain a greater understanding of the materials used in our designs, the below data sheets have been supplied by atl composites, and contain all of the technical data you could need regarding the composites we use. in addition are articles or documents written by jeff about certain systems used on our designs and why., all technical information and data sheets on west system/duflex/durakore provided courtesy of atl composites. for more information please see the atl composites website here., documents library.
Information Sheet – CE CERTIFICATION PROCESS
Kit materials' contents, so if you order a schionning kit, what exactly is going to arrive see an overview of the materials you will receive, and what each is used for during the build process. fibreglass cloth or tapes microspheres, microballoons or microfibers take a closer look and you can answer these questions., our schionning kits are a no nonsense, common-sense approach to building a boat. we offer great service, fast delivery and access to anything you could need for your boat straight from the supplier to your door. our construction plans and kits are sold with 100% professional boatbuilder support via phone and email, any time you're unsure or just need a second opinion, we're here..
Below is a quick glance at what your Schionning Kit will include and what each item is primarily used for, we hope this is helpful and if you should require more detailed information please don’t hesitate to contact our office.
DuFlex pre-laminated panels are the main and most important material used in our kits, predominantly in the flat panel designs, however they are used in Strip-planked designs also, though to a lesser extent. These panels are 2400mm x 1200mm and are CNC routed to speed up build time on our Wildernes X Series, as well as some of our power designs. For internal furniture, a paper honeycomb core is used instead of the end-grain balsa wood core that is used for main structural areas. The use of this is purely to save weight in the shell and therefore produce a faster, more responsive catamaran.
The kit process, building your own boat can be a daunting prospect, however to demonstrate each step in the kit assembly process, we've created this guide for you to study. as you can see our kits are the ultimate in building efficiency and have been streamlined over 30+ years to ensure that you're on the water faster and with less effort., how does it all go together.
The first step to building your dream catamaran begins with a strongback – this is a square frame used to position the temporary frames that will be used to form the hull shape. This frame will be set up and must be square and accurate, a string or laser level can be used to achieve this.
The forebeam is now installed along with the striker attachment fitting, as shown above. The bridgedeck is installed shortly after and taped onto the bulkheads with webs installed, this now completes what is a quite stiff and strong platform to work on.
Now that the bridgedeck is in place, the forward webs and dash will be fitted. At this stage, all furniture and internal work begins, with the main panels left off for ease of access when working.
Schionning material choices, solutions that work best for catamarans & why, our designs are based on cored composite construction techniques using west system epoxy resin and knitted fabrics. but given the range of today's composite technologies, which solution works best for catamarans and why written by jeff schionning, selecting the correct materials, resin choices.
It also fully protects the boat against water absorption and it can not develop the dreaded Osmosis.
We choose ATL Composite’s resin systems for their superior quality, reliability and value for money.
Having worked closely with the ATL Composites team and their products for many years, we know we can stand by their material solutions, and rely on great service should something unexpected happen.
This may not seem important but when working with a material for an extended period of time, the small things make all the difference.
Balsa has very good values and we can produce a shell using a very light laminate. It will be very stiff and very resilient to fatigue.
It has exceptional qualities including very high compression strength, extremely good sheer capabilities and fantastic sheer stiffness.
Compressive strength is the resistance to collapsing when pressure is applied perpendicular to the surface as when pushing directly onto the material with the point of your finger. Balsa is far stronger than Foam (80kg/cubic metre) in compression.
Balsa is also very strong in shear. This is when the core sample is held flat between your hands, one hand slid one way and the other slid the opposite way, when the core tears through the middle the core has failed in sheer. The amount of stretch you feel before the core shears is shear stiffness. To compensate for sheer weakness the core is made thicker. So 13mm Balsa may be equal in sheer to 19mm Foam.
(80 to 200 kg/m³)
There are many boats sailing that are built from foam as it’s mechanical properties are good for boat building.
The end result using foam core amounts to a very similar total boat weight. Professional builders can achieve a good result but usually use vacuum bagging and very good molds to achieve this.
Balsa can absorb water. It needs extreme neglect to rot (very unusual). Water soaks along the end grain quickly. It travels very slowly across the grain. We use balsa under the waterline especially because of it’s high compression strength for beaching etc. any core type must be sealed. Damage to all cores results in the same sort of repair. Notice a damp spot remaining when drying out to anti-foul… simply grind back the surface glass exposing the core, dry it out and re-glass – it’s that easy.
Timber cores are cheaper than Foam in most cases.
A light, high tech cat returns a far better (often 2 – 3 times) re-sale than lower tech materials. Often saving $10,000 on materials initially, loses $200,000 on re-sale – a serious reality.
Our boats can be built using Balsa, Foam or Western Red Cedar. Combine strength, stiffness, lightness and cost, with ease of use – it just makes good sense!
Ed Horstman designed TRIMARAN and CATAMARAN plans are drawn for the first time builder. Plans are concise and clearly drawn so the builder can easily follow each building step. Designs are continuously updated with your input and new ideas. Plans include full size patterns to 63'. The larger TRI's and CAT's have full radius hulls.With no lofting you build right away. The DESIGNER'S book TRIMARAN and CATAMARAN CONSTRUCTION is part of the plans (over 21') and covers all phases of construction. Plans are leased to build ONE boat, NO time limit. Tri-Star designs are proven designs, sailing the seven seas since 1964. Free consultation is provided to the original non-professional builder till he or she is sailing the seven seas. All boats may be built with flared hulls, with the exception of the TRI 25, TRI 26MT, CAT 27PC and the CAT 27. A DESIGN FEE for customer modifications to stock plans. Small, Fast Catamaran Design
TRI-STAR CAT 14 Plans $ Slightly Larger, Fast Catamaran Design TRI-STAR CAT 19 Plans $ Trailerable, Fast Catamaran Design with berthing areas TRI-STAR CAT 27 PC Study Plans $ TRI-STAR CAT 27 Study Plans $
TRI-STAR CAT 34 Plans $ CAT 36 designed as a spacious, fast enjoyable sailing cataramarn with accomodations found only on much larger yachts.
TRI-STAR CAT 36 Study Plans $
TRI-STAR CAT 38 Study Plans $
TRI-STAR CAT 41 Study Plans $
TRI-STAR CAT 51 Study Plans $ TRI-STAR CAT 55 Study Plans $ TRI-STAR CAT 55 Plans $ | ||||||||
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By Robert Bowman | Posted On Sep 15, 2022 Updated On May 03, 2023
The story of the evolution of the power catamaran can be broken down to a simple act of marital duty. it was the 1940's and Ray Leger loved to fish off of the California coast with his wife Evelyn. Ray had been a carpenter and capitalized on the booming Southern California housing market after World War 2, later using his skills and equipment to construct fishing boats. Evelyn would routinely suffer from seasickness, a problem that Ray needed to solve in order to keep fishing. Knowing that a catamaran offered greater stability, Ray set out to build one with outboard motors. The first one, an 18-foot cabin cruiser, was outfitted with twin 33hp outboards. By the 1960's, construction had moved to fiberglass hulls and the popularity quickly soared.
Today, power catamarans are among the fastest growing segments in the marine industry, as are sailing catamarans . A recent report shows that the global catamaran market as a whole is worth over $4 billion and has an annual growth rate of over 6%. That's nearly double what the average CAGR (compound annual growth rate) is for the boating industry in total.
The transition to power cats really came from charter customers in the Caribbean that would vacation on sailing cats in the BVI's for weeks at a time. The catamarans offered greater stability, but also an incredible amount of space on board thanks to the wider beams. But people on vacation enjoying the trip would end up using the small engines most of the time as sailing comes with a certain amount of effort. Now it's common to see power catmarans in charter in the Caribbean, as well as privately owned boats behind someone's house.
As more boaters get exposed to the benefits of power catamarans, the number of builders has grown as well. Power cat brands like Aquila Boats , as an example, weren't around in the early 2000's, but are now a common boat to see all over Florida or the Northeast. Prestige Yachts also just released their very first power cat into the market, the M48. Trying to claim that one power catamaran builder is the "best" among all of the others is a tough decision as there are many factors. If judged by number of units sold over the last 10 years, then Leopard is the best power catamaran builder in the industry. Looking at boats sold globally in the MLS over the last decade, Leopard Catamarans sold 40% more vessels than the second leading power cat builder, Fountain Pajot . Other notable power cat brands that led in overall sales were Endeavor, Lagoon, and Aquila.
(Below: On the extreme luxury power catamaran market, the Sunreef 80 is among the best.)
Video by: @NautiStyles
While the number of boats sold into the marketplace is a sign of strength in a builder, it also may not necessarily equate to 'being the best power catamaran' in terms of quality. Like with monohulls, there are varying degrees of both quality and price when it comes to the subsects of the power cat industry. Both Sunreef and Horizon Yachts have expanded into large luxury power cats that, even when more than 10 years old, can still command more than $2 million as an asking price.
One way to tell if the catamaran you're buying is well-recognized for its quality is to look at some of the recent award winners. Many of the editors of multi-hull focused magazines are experts in this category and have real-life experiences on dozens of different models. Here are a few notable ones:
(Below: The new Fountaine Pajot MY4.S offers a new 'sport top' style for the longtime catamaran builder.)
Whether you're purchasing a new or pre-owned power catamaran, its resale value is of the utmost importance. Nothing can stifle your enthusiasm when you are trying to sell your existing yacht only to have it sit on the market for a long time while diminishing in value. If this is of concern to you, the best advice is to stick with the more mainstream, reputable catamaran builders. Boats with odd layouts, underpowered engines, outlandish decor, and other out-of-the-norm equipment can cause your boat to sit on the market longer than anticipated.
The market demand has also improved in recent years. Over the last decade, power catamarans took roughly 330 days to sell. Almost a full year! Since 2020, however, that amount of time has decreased by 19%. Among the builders that sold within 100 days of hitting the market, Aquila, Endeavor, Fountaine Pajot, Leopard, and Robertson & Caine were prominent.
(Below: The Aquila 54 Power Catamaran has a tri-deck design with a beam of over 25-feet.)
At United Yacht Sales, we have over 250 experienced yacht brokers worldwide. Many have years of real hands-on experience with power catamarans, sailing cats, sailboats, and other similar vessels. We can assist you in the sale of your current yacht, or represent you in the purchase of a new one. Call us today at 1-772-463-3131 and we will connect you with the right sales professional that perfectly sits your needs and situation.
Also Read: Are Power Catamarans Good In Rough Water?
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It’s a given that catamarans are more sensitive to weight and loading than monohulls. Catamaran builders strive to build the lightest boats they can without sacrificing strength and stiffness, and have adapted new building techniques and materials to meet this target. Cutting weight allows more passengers and gear without sacrificing performance.
And the marketing materials reflect it–they load every review and website with polysyllabic technical jargon describing the design and production choices each builder made to deliver the best boat they can.
But when you’re reading a brochure and you come across phrases like “ hand laid bidirectional GRP ” or “ vacuumed bagged e-glass with vinylester resin over a Divinycell core ” do you know what that really means?
All modern production catamarans are made with “FRP” construction (for Fiber Reinforced Polymer). Composites aren’t new–it’s just using materials together to strengthen the whole assembly. Straw was added to bricks centuries ago, and steel reinforced concrete is a staple of construction over the last century. For boats, it’s the use of stranded fibers and cured resins which make FRP different.
The term “FRP” doesn’t get into the technical detail of which fibers and which plastics, and how they’re put together to build your hull. There’s a wide variety of fiber types which can be stranded, woven, chopped or sprayed in a varied of patterns then combined with several types of resins to make hulls with different characteristics.
Some FRP techniques produce lighter, stronger shapes, while others are quicker to build and less expensive to produce. The choice of technique is a function of many factors, from the number of hulls and parts to be built, the type of parts, the budget for the project, and many design specific requirements for weight and strength.
The principle behind all FRP construction is the same – you lay our fibers in the shape you need, then saturate them with resin, removing all the air and voids you can. Resin is left to cure, then the piece is ready to finish and use.
The reality is more complex, since building a boat isn’t like making a flat board or a simple door. You’ve got a complex shape with a designed set of curves to build. “Tooling” is the set of shapes to make the boat parts; molds to cover with fiberglass to get the right shapes.
That’s what makes FRP so effective – you can make almost anything out of it. But to do so requires a lot of choices about what you need for the project at hand.
There isn’t a “best” all around material or technique choice for all jobs, and sometimes a lower cost technique or easier to work with material may be the better solution to the problem.
Fiber choices in the last few decades have expanded past the glass fibers used in the first mass produced boats in the 1960s. FRP construction wasn’t new even then, they built the first composite boats using modern fiberglass in the 1940s.
The major fibers used in marine construction fall into three categories – glass, aramids, and carbon. The primary differences are in the strength to weight ratios of the fibers, durability, elasticity, and cost. Some construction may use blends of fiber types to combine performance characteristics.
Glass – the most common material still, because of its low cost and versatility. The most common variety used in GRP (Glass Reinforced Polymer) is “E-glass” which refers to its strand size and mineral content. Other grades have different and sometimes better mechanical properties, but may be more expensive and less appropriate for boat building use. Fiber sizes run 10 to 25 microns for E-glass, though other grades may be smaller.
Brands like Leopard, Lagoon, and most higher production volume builders use E-glass.
Aramids – this includes brand names like Kevlar, Technora and Twaron. They have higher tensile strength than E-glass, and resistant abrasion and punctures. Kevlar is a common choice for bullet proof body armor, and can built a tough, lightweight hull. The materials can be difficult to work with, as it is very tough to cut the cloth. It is often blended with carbon fiber or other materials – Catana is known for using Twaron blends in hull construction.
Carbon – the ultimate in lightweight, strong construction material. Carbon fiber is the most expensive fiber, and is available in a variety of weights, grades and strengths. Fibers are smaller than glass – down to 5 Micron.
The lightest, most expensive hulls are made from carbon, but a catamaran builder may use carbon in places other than the hull to add strength and stiffness. Carbon boards, rudders, and reinforcing structures can enhance performance without driving the price of the boat beyond reach. Carbon is the fiber of choice for many custom builds, racing cats, and Gunboat.
Fibers are woven into matting and cloth for construction. Depending on the application, different weights of cloth and cloth patterns and weaves may be more appropriate for the job.
Cloth weight refers to the weight per square yard (or meter) of the cloth. A square yard of nine ounce cloth weighs nine ounces. The heavier the cloth, the stronger it is in a laminate.
Fibers carry loads along their length, so cloth weaves have directionality to their strength. Most builders use several layers of cloth with different orientations to give good universal strength to hulls. Specific FRP applications with strict load-path requirements may have more unidirectional fiber layering – for example, a chainplate manufactured from carbon fiber may use unidirectional fiber.
Cloth – fiberglass cloth is commonly used on outer layers of composites. Cloth may have unidirectional or bidirectional strength. Bidirectional cloths have maximum load strengths in two perpendicular directions. Variations on weaves like a modified twill allow a more flexible cloth for better shaping around complex molds.
Mat – is omnidirectional strands of fiber compressed into a cloth. This is often held together with a resin soluble glue, which makes mat great at conforming to mold shapes without folding and bunching as it collapses when wetted. Because the strands do not align, fiber strength is the same in all directions.
Woven Roving – a heavier cloth made from larger bundles of strands. Woven roving allows for quicker buildup of material and strand weight.
Most FRP layups include multiple layers of different cloth and mat. Finished layers may be finer cloth over courser cloth, over woven roving and mat.
Three primary resins are in common use in marine construction – polyester , vinylester , and epoxy . All resins have materials safety concerns and require care in their use and handling.
Polyester is the least expensive and requires breathing protection because of the VOC emission (Volatile Organic Compounds…nasty, smelly fumes). It doesn’t have good bonding/gluing capability, and should only be used with glass fibers for structural building. Some polyester resins are referred to as “isophthalic” resins.
Vinylester is chemically similar to a hybrid of polyester and epoxy, and performs best with fiberglass. It shouldn’t be used in high strength applications with carbon or aramid fibers. It has some adhesive qualities which polyester lacks, it shrinks less during curing, and has better impact resistance.
The added strength of vinylester coupled with increased water resistance makes it an attractive option for many catamaran builders. It costs less than epoxy, but still has better performance than polyester.
Epoxy is the most expensive, but is three times the strength of the others. It offers the best adhesion and the only resin for building structural elements with carbon and aramid. It resists water intrusion better than the other resins, resists blisters, emits no VOCs, and shrinks less. The major drawback is it is more brittle if it takes an impact.
While epoxy is “the best” in terms of strength and ease of building, there are many applications where other resins are appropriate. Budget is a big driver – a boat made from E-Glass doesn’t need epoxy resin, and considerable cost savings to meet a construction price target may drive the choice.
They can build quality boats from all material combinations, but price and performance will drive materials choices to keep some boats more affordable.
What’s the best way to make fiberglass strong? To a point, you can make it thicker. As it gets thicker, it gets heavier. A hollow shape can take more compressive load than a solid one of the same weight, and the same principle applies to fiberglass construction.
Consider an I-Beam used in building construction. It has the same strength (or more) as a solid rectangular beam of similar mass. The compressive load on the beam is supported by the outside edges of the material, the metal in the middle doesn’t contribute much to the strength. So we can remove metal to get the “I” shape while still keeping those sides rigid, making a lighter girder with less material.
The same principle applies to cored construction with fiberglass. Making a sandwich of two layers of fiberglass with a light core between them allows for the greater strength with weight savings.
There are drawbacks – the biggest risk is damage which breaks the skin, which can let water into the core. Earlier cored construction used materials prone to saturation and rot if they got wet. Some builders opt to do cored construction above the waterline and solid below to minimize some of these risks.
But the advantages in weight savings and increased stiffness offset the drawbacks, and there may be a few other side effects like sound and temperature insulation. Like resins and fibers, core materials offer distinct advantages, disadvantages and price points.
Most builders have adopted a hybrid approach, building solid hulls below the waterline, and cored hulls and decks above. This gives a balance of weight and safety.
Balsa is light and inexpensive. The first cored construction used balsa, but it has the disadvantage of being wood. As a natural material, if it gets wet it can rot and break down. Builders use “end grain” balsa – shorter cross cut sections – to prevent wicking of water if there is an intrusion.
Closed cell foam cores give good strength to weight savings while minimizing water intrusion. If you get water in the core, it won’t spread very far. Divinycell is a popular PVC foam core, though there are several choices with different densities and compressive strengths.
Some foam cores are not suitable for heat treatment, but infused or vacuum bagged boats like the Outremer and PDQ do well with it.
Honeycomb cores are often the most expensive, but also give some of the best strength to weight ratios. Honeycombed cells made from resin cured aramid papers are some of the best, but also among the most costly. They offer good stiffness, but can be hard to shape. Aluminum and other resin-infused papers are other core materials builders can choose from.
When building a hull, there are optimal ratios of fiber to resin saturation for target strength and weight. Too little resin and you may not have enough strength (or worse, voids and gaps), and too much, and you’re just adding weight without adding strength. Resins are also a significant material cost in building the boat, so over application not only increases weight but adds cost.
There are many ways to assemble the cores, fibers and resins to build a finished laminate hull – we’re addressing the most common in boat building. Each approach has strengths and limitations, and an impact on the bottom-line cost to build the boat. Any voids or air pockets in the laminate can be disastrous; these techniques have been developed to increase saturation and reduce the risk of voids.
As the name implies, this is the application of resin by hand to cloth as it’s laid into a mold. Wetting is done with a brush, and the laminate is rolled out to remove any air pockets and voids. This is the simplest way to lay up fiberglass, but also the least precise and consistent and will use the most resin.
Skilled craftsmen have built some of the finest vessels in the world this way. Though it’s more popular with monohulls, which are less sensitive to weight, many catamarans built with hand layups on open molds are still out cruising and performing well.
Using chopped-strand fiber mixed with resin, a “chopper gun” can spray the mixture into a mold to lay down the composite. A consistent thickness can be difficult, but this is a low cost construction technique which makes a very resin-rich laminate. Using sprayed fibers gives lower strength in all directions compared to meticulously laid down mat and bi-directional cloth. But it is a quick technique popular with mass produced, smaller boats.
It is an excellent technique for parts with complex geometry where weight is not an issue, but you will not see it often in catamaran construction. It’s heavy with resin without any resultant increase in strength.
When an open molded component has been laid up and wetted with resin, vacuum bagging takes the process a step further. After the wetting is complete, air tight plastic bagging is secured around the wetted area, and the air is pumped out of the bag. The vacuum pulls excess resin out and collapses air pockets.
The goal is to get thorough wetting and produce as strong a laminate as possible without excess resin. Knysa and Leopard are two builders that use vacuum bagging on their hulls to reduce weight.
For resin infusion the cloth, matting and core is laid in place dry, then sealed in an air-tight bag. A vacuum pump attaches to one side of the bag, and on the other a feed for resin. The vacuum sucks the air out of the dry cloth stack, then pulls the resin through the stack, infusing and wetting it.
Resin infusion, when done right, gives the lightest, strongest laminates with no voids and the minimum resin weight for maximum strength. SCRIMP is a variant of the resin infusion process used by some builders, including TPI which build many early Lagoon cats.
Using pre-preg (for “Pre Impregnated”) cloth for your laminating gets rid of the resin bucket. They manufacture cloth with a partially catalyzed resin pressed into it, then it’s chilled or frozen to stop the curing process. There is no need for seperately mixed resins, and there’s no worry your resin might “go off” and harden before you’re done wetting the cloth. Instead, the cloth is assembled, vacuumed, then heated to kick off the curing process.
There are both advantages and disadvantages to using pre-preg for your laminate work. The big disadvantage is the cost; it is most expensive material to use. You also need to chill and store the cloth until you need it, though some can be at room temperature for a couple of weeks without kicking off. And you need an oven which requires some clever tricks if you’re building a forty or fifty foot boat.
But the strength to weight ratio will always be perfect. High tech honeycomb cores are best suited to pre-preg lamination, and without racing against resin cure times, you can ensure perfect cloth placement and precise layout in the build process.
The primary use for pre-preg in boating is high performance race boats. With catamarans, pre-preg may be used high load parts, like Gunboat does for foils and rudders.
Across the catamaran building industry you’ll find almost all the above techniques and materials used, though some are less common. You aren’t likely to find chopped strand sprayed layups in ocean going cats, and hand layups can lead to heavier hulls than weight sensitive catamaran designers prefer. Most manufacturers have moved to vacuum bagging or resin infusion, with a few of the highest end boats using pre-preg for key components.
Built by Robertson & Caine in South Africa, the hull material is vacuum bagged, end-grain balsa-cored E-glass with polyester.
Hand laid, bagged vinylester over an Airex foam core in the hulls.
Earlier Prout catamarans like the Snowgoose 34 featured hand laid solid FRP hulls and decks. Over time they switched to foam or balsa cores for decks and above the waterline.
Older PDQ boats were made from vacuum bagged vinylester – solid below the waterline and cored with CoreCell foam above the waterline and in decks. Newer PDQ models switched to epoxy resin.
All glass is vacuum bagged. Below the waterline is solid E-glass and vinylester. The rest is unidirectional, bidirectional, and triaxial cloths over a Nida-Core polypropylene honeycomb core with isophthalic and vinylester resins.
The Gemini cats are built with a solid hand layup of woven roving and fiberglass mat and polyester resin. Decks are cored with end grain balsa. The Gemini 3200 introduced vinylester resin into the layup to prevent blistering.
Older Lagoons were SCRIMP infused vinylester with and end grain balsa core above the waterline and in the decks.
Newer Lagoon catamarans use polyester and vinylester resins, also infused with balsa cores above the waterline and solid below.
With a carbon fiber inner skin, Catana also uses Twaron aramid fibers in the sandwiched hull over a foam core.
Primary hull construction is resin-infused vinylester with a balsa cored hull and deck.
Beneath the waterline, Outremer uses a single layer, solid vinylester laminate for safety. The hulls and deck are vinylester with a Divinycell foam core. They stiffen certain components with carbon for rigidity and durability.
Gunboat hulls are epoxy infused carbon fiber with a Nomex honeycomb core. They build dagger boards and other high load components with pre-preg carbon.
Owner of Hallberg Rassy 53; world explorer.
Excelent. Thank you for this I learned allot. Johan
Very straight forward information. Thankyou for doing this.
Damn…What an Amazingly Informative Article. *Cheers*
Outremer publish on their website that they use polyester. Not vinyl ester as you have stated.
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From 67 to 78 Feet
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This usually means anyone at the front or sides of the boat takes most of the jostling,"Myers says. "The catamaran-style hull delivers ride comfort, smoothness, load distribution, and stability."That stability draws anglers to powercats of typically 20 to 40 feet; and cruisers to sailing cats 40 to 60 feet and beyond. — Rich Armstrong.
The lifespan of a power catamaran largely depends on its build quality, materials used, and how well it's maintained. With proper care, a power catamaran can last for several decades. The engine's maintenance significantly impacts the catamaran's lifespan, with gasoline engines requiring maintenance at 1,200 to 1,800 hours and diesel engines at ...
ECO 55 Power Cat Plans. The ECO 55 power catamaran is an affordable DIY power catamaran. As the owner proved the boat is a capable coastal cruiser. The inside layout is the same as for the ECO55 sail version but the underwater shape is changed. The cockpit is wider and has a size of 1,45m x 2 m. With the bigger size normal deck chairs can be used.
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If you were to build a 40-foot (12.1-meter) catamaran, your cost of materials would range between 20-30% of the total cost. Therefore, for $300,000 total, the boat's materials would range between $60,000 and $90,000. The hull tends to range between 15-35% of the total build.
We went to Thailand to check out the build of our new longreach58 power catamaran. It was great to chat with James Dewing the boat builder and owner of @Long...
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We are renowed for building large custom made luxury yachts: catamarans, power boats and superyachts. We design, build and charter yachts from 60 up to 200 feet.. Sunreef Yachts Eco is a renowned builder of bespoke luxury yachts, power boats, and custom zero emission catamarans that reconceptualize ocean voyages.
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The introduction of this substantial kitty is timely since the large power catamaran market is exploding and builders can't keep up with demand. Hull #1 of the model is expected to make a lot of noise and snap heads clean around. Let's take a look. Above: The Sunreef 100 Power catamaran leaving the factory. Photo: Sunreef Yachts.
Photo via World Cat Boats. World Cat is one of the most recognizable brands in the world of power catamarans — in fact, according to the company they're the largest producer of power catamarans in the world. Their line is a mix of center console and dual console fishing and family boats ranging from 23' to 40'.
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The DESIGNER'S book TRIMARAN and CATAMARAN CONSTRUCTION is part of the plans (over 21') and covers all phases of construction. Plans are leased to build ONE boat, NO time limit. Tri-Star designs are proven designs, sailing the seven seas since 1964. Free consultation is provided to the original non-professional builder till he or she is sailing ...
At United Yacht Sales, we have over 250 experienced yacht brokers worldwide. Many have years of real hands-on experience with power catamarans, sailing cats, sailboats, and other similar vessels. We can assist you in the sale of your current yacht, or represent you in the purchase of a new one. Call us today at 1-772-463-3131 and we will ...
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Leen 56. The Leen 56 power trimaran is a long-range cruising multihull, perfectly capable of transatlantic voyages or living aboard in high latitudes. Built in a highly efficient, new hybrid composite panel system, this power trimaran has a range of 5,000 miles and may only be fueled up once a year. 3. Gallery.
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Build a small boat first to get familiar with some basic techniques and pitfalls, also helps with reading and understanding building plans. A catamaran to live aboard on is quite an undertaking. Might also not be suitable for everyone. Also the sea is a harsh environment frequent maintenance on a boat is something you need to anticipate.
The 70-foot power catamaran is the epitome of maritime sophistication, meticulously crafted for the ultimate in luxury, space, and performance. Tailored to the desires of the elite yachtsman, these vessels offer an impressive breadth of amenities and expansive interiors that epitomize comfort and style. The twin-hull configuration of the 70 ...
POWER CATAMARANS. From 67 to 78 Feet. EXPLORE THE WORLD BY MOTOR YACHT. Designed for offshore cruising, these catamarans truly are jewels of the sea and references in their category. These Lagoon motor yachts immerse you in a world of freedom, of elegance and comfort. Imagine the catamaran of your dreams, made possible through our ...