From 3D to reality, getting it right

While we have had the entire boat 3d modeled and designed prior to production of our molds there is nothing quite like sitting on the real thing and getting a feel for everything first hand. So at this stage in the development we have a dummy mast in place on our deck, and we hot glue deck hardware in its designed locations. Then, we re-enact the use of the boat going through various scenarios, different sails and different conditions to ‘feel’ how the systems work on a 1:1 scale. This has enabled us to maker small tweaks to hardware placement for the benefit of good ergonomics, and practical use of the 880.

#Corsair880 #880trimaran

880 production underway!

The first of our new 880 series has finally started production. With hull and deck now fully infused, we have actually begun weighing parts which are coming in per estimates and in some cases under estimated weights. This is part of our tight weight control program for the 880 model.  This positive news comes as a result of a last-minute decision to change our process to the more costly infusion process. This was done primarily as it delivers a far more consistent weight and structural result with a reduced carbon footprint due to the reduced emissions and consumable waste. We have also managed to optimize the deck laminate by replacing certain structural areas with carbon fiber instead of straight more commonly used e-glass. This gives us a carbon ratio of approximately 20% on this model resulting in a lighter, stiffer final product. Our first deck came out of the mold at just 166 kilograms, a good 11 kilo’s under our earlier predictions so positive news from production!

The last of the tooling components for the construction of the all-new trimaran Corsair 880 were completed this week.  That means molds for the hulls, deck, floats, beams, and all internal components are now in place.  The parts will now be repositioned to their choreographed production station, ready to start construction of the first Corsair 880 trimaran.

Shown here is the main hull mold, which gives the new model its advanced underwater shape.

The following images show the deck components – this gives the cockpit it’s broad shape, and the foredeck on the central hull.  That foredeck mold also reveals the place where the toilet will sit below deck, and the recess for the waste tank.

The black components are the internal parts for the Corsair 880 trimaran.  Shown here is the internal mold that reveals the shape underneath the settee.  And the next black part is the other side of the main hull – the galley.

Finally, the molds for the new aerodynamic beams are shown, along with the assembled beam.

Corsair is now embarking on a new stage of production as we build the prototype Corsair 880 trimaran.  So look out for exciting updates as the very first boat is built!

The busy Corsair Marine factory is full to the brim making multihulls.  So many of the key tooling components for the Corsair 880 are being constructed outside of the main facility and then shipped or driven in.  It was an exciting day today as the first of such components shipped out.

Seen in the first picture is the port half of the main or central hull mold.  Note that the tooling for this boat is supported by extremely durable and stiff steel framework – reflecting our intention to make every single boat to the same high standards, and have molds intended to match the long lifespan that all Corsair models should have.  It also means these molds are stong enough to be shipped, or moved frequently.

In the second picture is the foredeck mold of the main/central hull.   The large structures which here point upwards (the mold is “upside down” in this shot) are actually recesses for the toilet and waste tank.

Back in the Corsair factory, tooling work has begun on the masts for the Corsair 880.  Both mast options will be from Carbon Fibre – the Sport mast being 13.8 metres, and then the standard 12-metre mast.  Carbon masts offer obvious performance benefits, but also help keep the overall weight of the boat down, and make trailering, mast raising, and general handling of the mast an easier operation.  Seen in the 3rd photo below is the first mold for this crucial component.

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880 Construction Update 6

Ok, so as you have seen in the last few updates the Corsair 880 trimaran is really starting to take shape now. At this stage in the game tape measures and calipers are our go to tool. Everything is getting checked and rechecked, we really need to nail this deck, so many other parts are relying on an accurate deck mold in order to properly marry up with the other components. We cannot stress enough how critical this stage is!

Another aspect of these checks is to check the ergonomics and practicality of the design. After all this is the first time we have sat inside the cockpit and walked the deck of what will end up being a 1:1 scale model of the real thing. So we have laid out mock ups of the hardware and work our way around the systems and usage of the boat, all the while making sure everything works, is comfortable and practical. During this exercise we were just blown away at how spacious this boat has turned out, remember this is a trailerable 29′ trimaran. Check out the images below and see just how big that cockpit is, in a few of the shots I am sitting in the cockpit as I would sailing and have included my legs in the shot to give you a sense of scale, i’m 5’11” btw.

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While work continues on the hull and deck of the trimaran Corsair 880, beam plugs are shaping up nicely. The beam plugs have been constructed in a very similar manner to the larger plugs. This begins with designing the framework on the 3d model before exporting these to a CNC machine to be precision cut and then assembled. These frames are then covered, glassed and filled and fired before a final top coat is applied and a mold is taken. The beams on a folding trimaran are under an incredible amount of load, a lot of engineering goes into the design and internal structure required to keep these impressive structures in tact.

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