CADCAM takes boat builder out of the stone age

The PowerShape CAD modeller and PowerMill CAM system are used to manufacture master models of the yacht hulls produced by Numarine in Turkey using the resin infusion process.

The use of Delcam's PowerShape CAD modeller and PowerMill CAM system to manufacture master models ensures the quality of the yacht hulls produced by Numarine in Turkey using the resin infusion process.

This Istanbul-based company is one of the youngest and fastest-growing boat builders in the world.

Numarine was founded in 2002 by owner Omer Malaz.

In the short period since then, the company has grown to almost 200 employees, designed four yachts of its own, won a contract to build boats for UK company, Pearl, developed one of the most advanced production facilities in the industry, and attained a reputation for the sophistication, power and technology within its products.

The key to the low weight, safety and reliability of the Numarine yachts is the use of infusion technology developed jointly with the Swedish firm, Diab.

The process, in which the resin is infused into the reinforcement under vacuum, combines the benefits of sandwich composites, such as reduced weight and increased strength, with the processing, performance, and health and safety advantages of infusion moulding.

The system uses a specially grooved core, which not only enhances the structural performance of the component but also acts as the resin transfer medium.

By eliminating the need for sacrificial mats or nets, the cost of consumables is reduced significantly.

The infusion process also allows faster resin flow rates, and so gives shorter cycle times and the ability to produce larger components without the need for secondary bonding.

In addition, the Diab system enables the production of composite components that include high volume fractions of fibre and have an excellent surface finish.

Of course, like any moulding process, the infusion system is dependent on the quality of the mould, which is why Numarine values its Delcam software so highly.

All the component designs are first transferred into Delcam's PowerShape CAD system to create the master model shapes, with any added split and run-off surfaces.

PowerShape is also used to divide larger components into manageable sizes.

The models are then programmed in PowerMill for production on Numarine's giant CMS five-axis mill, with a 12.5 x 8.5 x 4m working area.

The combination of PowerMill and the CMS machine gives impeccable accuracy as well as speeding up the introduction of new designs when compared with traditional methods.

"In general, the level of technology in the boat-building industry is 60 years behind the aerospace industry and in the stone age compared with the automotive industry", commented Muzaffer Erdal Kilic, General Manager at Numarine.

"The Delcam software is contributing towards closing that gap, plus our reseller CAG CAD/CAM has always helped us very promptly with any problems".

"However, within our company, nothing is taken for granted", he added.

"We spend a lot of time and effort in thinking about ways to improve our methods".

"We have proposed several ideas to Delcam to develop the program for our needs and we are seeing regular improvements".

"For example, we are looking to develop methods for five-axis polishing of the hulls so that we can replace hand polishing".

Back to top