Lighter, stronger and safer boats

An Auckland company's commitment to research is enabling the boatbuilding industry to benefit from its advances in composite materials technology. The result is boats - including those that will contest the next America's Cup regatta - that are lighter, stronger and deliver better performance as well as increased safety in a cost-effective package.

The world-class work going on at High Modulus convinced the Foundation for Research, Science and Technology to back the company, providing more than $400,000 to support its international drive.

High Modulus, with engineers in Auckland, Britain and France, is one of the world leaders in the use of composite materials in marine structures, through its expertise in structural design and process engineering.

While composite materials are found in many applications, High Modulus is one of only two significant players internationally in the marine field. The latest research project extends its ability to capture the position of technical leadership in the marine market.

High Modulus senior engineer Michael Eaglen says it enables the company to accelerate plans to expand further into international markets and develop new marine products.

There are several components to the new research, but a key focus is developing new boat strength test methods to replicate slamming. This occurs in rough seas when a boat leaps over waves and slams back down on the water, generating high dynamic loadings.

The combination of an analytical practical experimental approach to the study provides High Modulus with new knowledge to design structures and materials for boats, particularly around-the-world racers, superyachts and luxury and performance powerboats.

High Modulus estimates that with its highly qualified staff and the foundation investment it has been able to achieve in three years what would otherwise have taken eight. The foundation provided half of the $800,000 project cost.

Eaglen says he is confident the knowledge gained will result in the development of new products. Possibilities include off-the-shelf structural beams already fitted with engineered reinforcing in the way of holes for wiring or plumbing, and plates containing specifically tailored ply orientations to improve bearing strength.

There is pressure on the 15 New Zealand-based consulting engineers at High Modulus to meet an increasing commercial workload at the same time as committing to a major R & D programme.

Present activity ranges from "proof of concept" vessels for the United States military to the America's Cup.

The company has been involved with the cup since the first fibreglass 12m yachts were built for our first challenge in Fremantle in 1987.

Managing director Richard Downs-Honey says for R & D to have value it must trickle down into the day-to-day design activity.

"The projects we take on are those that deliver solutions to the specific issues facing us rather than simply adding to the general knowledge bank," he says.

"We have a long track record in developing R & D projects to answer a specific issue or address a defined programme. The foundation investment has enabled us to develop a more holistic approach to the bigger problems we face.

"Being a leader in marine composite technology isn't just about designing boats that win races and don't break. The R & D is not simply about finding something new. It is using research to produce results in the construction, be it reducing weight, improving safety margins or delivering a more cost-effective solution to the builder."

High Modulus engineering expertise has helped to produce everything from reliable, robust, high-speed interceptor patrol craft for the Malaysian Customs to superyachts, including the 53m Ed Dubois-designed Salperton and Mirabella V, the world's biggest single-masted yacht.