5. Tools & methods

The latest technology in our design & manufacturing process to improve lead time and efficiency.

“Satellite industries”

Left and below: “The shipyard embraced a concept known as Concurrent Design & Engineering, a method of product development based on completing processes at the same time while involving all disciplines. A related process is Stage Gating, by which a project is divided into distinct stages separated by decision points known as gates.” according to Superyacht Times article about project 400, Sea Eagle (II)

“Both methodologies are commonly used in the aerospace and satellite industries with the aim of increasing time and cost efficiency while maintaining quality. ‘Basically, before starting each phase of construction we discuss what we want to deliver, what the details and implications are, and make decisions together with the departments that come after,’ explains Royal Huisman’s project manager.”

“Like a flatpack from IKEA”

Left and below: “We also add a lot of details during the CNC milling, like perforations for deck winches instead of aligning and drilling them afterwards. It basically means more accurate and efficient assembly a bit like a flatpack from IKEA. Another production improvement has been the adoption of modular skid fabrication. Instead of installing engineering components individually, the systems are assembled within a frame or skid for plug-and-play installation.

‘Skids allow us to build entire systems in parallel, test them onsite and install them as complete units. With as many as 20 skids on this project – from fuel and fresh water to AC and entertainment system – it makes the whole installation process faster and more effcient.’”  – From Superyacht Times article about project 400, Sea Eagle (II) 

Below, center: the XXL advanced composite rudder of project 400 was made by sister company Rondal and equipped with load sensing technology.

“The answer is glue.
Not any glue…”

Left: the long, low superstructure of project 400 contributes superbly to her sleek and purposeful styling. It also raised an interesting question for the engineers. A largely rigid structure made principally from a highly rigid component – laminated glass – is not going to flex in a seaway in the same way that the hull is designed to do. In those circumstances, how do you safely and securely attach the rigid structure to the flexible one without compromising either? 

The answer, perhaps surprisingly, is glue. Not any glue, but one with highly sophisticated properties, developed by aerospace specialists and classification officials especially for this project. With the rear section of the infrastructure conventionally welded to the deck, the forward section is glued, absorbing up to 2cm / 1″ of flex between deck and structure whilst also providing a permanently secure and weathertight bond. Likewise the complete superstructures of project 404 and 405 have a flexible bonding to the hull too.

Below: various projects under construction. Exoskeletons relieve heavy overhead work.