34′ (10.5M) Tender

So is this cool or what? The hull and deck molds have been shipped to Hodgdon Yachts of East Boothbay, Maine for parts fabrication. We are on to CNC cutting the remaining molds for the rest of the parts such as hardtop, bulkheads, hatches and other details. We are truly looking forward to seeing this one in the water!

Manufacturers Association of Maine Monthly Meeting

On March 11, 2010 Janseneering was pleased to host the monthly meeting of the Manufacturers Association of Maine. Headed by Executive Director Lisa Martin, the association is active in promoting the growth and success of businesses in Maine, a constant struggle considering what our state legislators try to do to prevent that (my comment, not Lisa’s). As such, they are also a great source of information and updates on legislative issues.

After the tour here, the group headed over to the Maine Advanced Technology Center to see the new Haas CNC machining centers used for instruction and training. Also on the agenda was a visit to the composites classroom with a review of its facilities and classes.

It was a successful evening and we look forward to the next opportunity to showcase our 5-axis CNC plug and mold making capabilities.

America’s Cup Race – We were there

This picture is taken from the BMW/Oracle Team website – congratulations for their America’s Cup Race victory. There were so many incredible pictures to choose from but this one gives you a very good idea of the scale of the mast we were involved with (yes, those white specks are crew members). You may recall in a previous blog post where I said there are many projects that we are involved with but cannot share those with you? This was one of those, however, we have recently been given the word that we can share this exciting project with our readers. Janseneering used our 5-axis CNC machines to cut the mast plug for the BMW/Oracle entry for the latest America’s Cup Race. Obviously, with a 35′ long working envelope we were not able to make it in one piece which is around 185′ long. Again, this is where the precision of CAD and 5-axis CNC come into play. We made numerous plug sections that were very accurately assembled by the Custom Composite Technologies crew into a single length plug. From that they crafted a carbon fiber/epoxy mold that was sent to Hall Spars in Bristol, Rhode Island, USA who then built the mast for BMW/Oracle.

I can tell you this – this is not the first winner we have helped make it across the finish line in first place. We plan on being there again, but …… you may never know about it.

A Day of Friendly Competition – Kart Racing

It can’t always be work and no play, so once a year we try to do something outside of the shop for fun. We headed over to Maine Indoor Karting for an afternoon of cart racing with some of our local suppliers/customers. These carts really haul and it gets pretty intense as you round the corners and get bumped into a spin, or you clumsily put your foot down a little too hard on either the brake or the throttle resulting in an adrenaline induced mess up. We had several races to test our mettle but as hard as we tried to beat him, Nate came out ahead of all of us. Did I mention Nate is probably the biggest gearhead of all and used to make a living as a photographer at NHRA events? Joining us were folks from Custom Composite Technologies and Menezes Marine Group. Trophies were awarded and celebrated with a couple of post race beers.

Who knows where 2010 may take us.

Vicem Boat Hull Model

Vicem Shipyard in Turkey is a world renowned builder of yachts of the finest quality. Vicem has launched close to 150 yachts in various styles such as sportfish, cruiser and classic, as well as custom designed and built yachts. Their quality is superb and attention to the clients’ wishes is beautifully executed.

Among its talented ranks of craftsmen is a model builder with an artistic touch that is hard to match. Vicem needed a model of their new 35m yacht. Since a 3D CAD file of the yacht had been created by the designers, it was decided to try a different approach from the traditional hand method of model construction. Janseneering was asked to provide a 5-axis CNC machined scale model that the Vicem model builder would use as a platform that would be completed by him with all the fine details and paint scheme. Janseneering machined the hull and deck with most of the features included. This high density foam model, complete with overhangs, stairwells, window mullions, seating and other components greatly reduced the amount of time needed build the model. The foam model was carefully packed into a crate and sent to Vicem in Turkey where the model builder turned it into a work of art. Be sure to stop in at the Vicem booth at the upcoming boatshows.

Janseneering is proud to have helped on this project. Model building has come of age through the use of CAD and CNC equipment, but it still demands the touch of an artist to bring it all together.

34′ Boat Hull Mold Ready to go Out the Door

Ready to leave, the 5-axis CNC machined direct hull mold is completed and set to be shrink wrapped for protection against the elements – it leaves tomorrow. The mold was placed on the 5-axis CNC December 21, 2009 and it is complete January 15, 2010, and that includes a week of closure for the Holidays. It is almost impossible, unless you throw a large crew at it, to do the same mold work with manual methods. The speed, accuracy, symmetry and fairness of CNC machining is hard to beat. From here, the mold will undergo final sanding, polishing and surface preparation for the laminate installation. The hull will be infused (VARTM) into the seamless surface mold. Next on the schedule is the deck mold for this boat. The base has been started and we are underway creating the frames file for cutting. Join us as we take you through the steps to get the deck mold into the same condition as the hull mold.

34′ Tender Takes Final Shape

We are at the final stage of the project where 5-axis CNC milling is under way, shaping and contouring the interior of the hull mold that has been sprayed with a high density putty. The advantages of a sprayed surface are that there are no seams to telegraph through to the finished part, it is homogenous and therefore the same physical properties over the full surface, and it is virtually leak proof, making for a perfect surface against which to use infusion, VARTM or other vacuum methods.

To give you an idea of the time frame, this part went onto the 5-axis CNC on December 21, 2009. Today is January 7, 2010. When you consider plant closure for the Holidays, it has been seven working days that this hull mold has been underway and that includes machining the previously sprayed foam layer. Deduct from that span two days for spraying the putty and you will understand how quickly this process can bring a part to prototype. In addition to the speed, the accuracy, symmetry and fairness of the hull mold surfaces the mold is a true representation of the designer’s original concept and 3D CAD file.

Sycara Fantail Cruiser

Last March of 2009 we had a short blog entry about the above custom 151′ fantail cruiser and some of the work we were doing. Sycara has been launched and it is a beauty! Please visit Custom Composite Technologies to see some of the work we made molds for, and then take a stroll on over to Burger Boats for a bigger picture.

DDG 51 Fairwaters

Back in March 2009 I mentioned the work we are proud to be associated with for the United States Navy, the DDG100 Zumwalt Class multimission destroyer program. See www.naval-technology.com/projects/dd21/ for additional information on this new ship. Janseneering has also been involved with the fairwaters for the ship the Zumwalt Class will replace, the Arleigh Burke Class of destroyers. The ‘old’ but current model has similar underwater fiberglass fairwaters that are produced from e-glass reinforcements and a matrix utilizing the Vacuum Assisted Resin Transfer Molding (VARTM) method. All trimming and machining of the laminated fairwaters is done on our 5-axis CNC machines. The parts are quite large and the machining that is required could not be done on anything but 5-axis machines, unless of course, one wanted to use multiple CNC machines and do multiple setups. We concurrently produce fairwaters for both class of ships. We make the cone/cylindrical shaped part just forward of the propeller strut.

Looks like a Blumonge

Well, okay so maybe not quite as puffy. We have covered over the open frames and longitudinals with sheathing and then sprayed about 60 liquid gallons of a two part reactive foam. The process gives us some leeway for quirks in the frames assembly so that when we machine the foam with the 5-axis CNC machine, we will get a slighter oversize cavity from the actual hull shape. Once the foam is cut, we will add a fiberglass/matrix layer and then a total covering of a sprayed high density putty. Much of the part will be easy to cut utilizing a mix of 3-axis, 4-axis and 5-axis machining tool paths. The old 80/20 rule applies here as well as in many other aspects of life.