IBEX 365 News

Diab’s Advanced Kits Mold New Technology Into the Future of Boatbuilding

Diab’s Advanced Kits began with an aim to improve efficiency. Prior to Advanced Kits, flat core sheets with standard finishes were forced into complex curves using 2D flattening. Diab’s proprietary software designs optimum grooves for each core piece.

“The initial reason we started the development program (for the Diab Advanced Kits) was to improve efficiency and the resin uptake for a marine foam kit,” said Peter Norlin, Diab’s Engineering Services Manager for Europe. “We wanted to find an “in-between” solution, between thermoformed and a GS kit— a solution that was cheaper to produce and quicker to place in a mold than a thermoformed kit.” “The transfer from a theoretical model into reality is always difficult. It was important to have several customers that were willing to try something completely new so that we could get feedback and make improvements.”

Traditional kits often have gaps between the core pieces when laid into the hull, he said. The improved fit of the Advanced Kits saves time and improves the overall fit, which in turn reduces resin uptake. That resin savings leads to overall laminate weight savings, providing for better overall performance of the vessel. Reducing resin uptake and cutting labor hours, in turn, reduces overall building costs.

Diab’s Advanced Kits are new to the market, and while Divinycell products have been used for marine kits for decades, not everyone is aware of this next level kitting, said Norlin.

“Winning the IBEX Innovation Award has called attention to our Advanced Kit offerings. Being recognized by IBEX makes our Advanced Kits more visible. We’ve already had inquiries and new customers because of IBEX.”

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What problems were the Diab Advanced Kits designed to solve?
The initial reason we started the development program was to improve the resin uptake for a marine foam kit. We wanted to find an “in-between” solution to thermoformed and GS kits, one that was cheaper to produce and quicker to place in a mold than a thermoformed kit.

Are there obstacles the kits will help builders overcome?
Traditional kits often have gaps between the core pieces when laid into the hull. This is because the rectangle sheet is difficult to fit into a shapely hull surface. These gaps can be difficult to fit and can hold excess resin which can “print” to the external surface. Other boatbuilders looking to reduce weight would try thermoforming their core kits. This requires investments in ovens, molds and skilled labor. And the results were not guaranteed, or necessarily repeatable.

How has your product changed the boatbuilding process?
The improved fit of Advanced Kits saves time and improves the fit, which in turn reduces resin uptake. That resin savings leads to overall laminate weight savings, providing for better overall performance of the vessel. Saved labor and less resin use also reduces costs.

In addition, the tighter tolerances between kit details in combination with the fact that the curvature grooves do not go all the way through the core thickness results in significantly reduced printing when infusing. For producers who paint after demolding, this considerably reduces the time needed for surface preparation work before painting.

Could you describe the innovation found in the Advanced Kits?
The innovation in the Advanced Kit is the fit to the form of complex geometry. Prior to Advanced Kits, flat core sheets with standard finishes were forced into complex curves using 2D flattening. Diab’s proprietary software allows us to design optimum grooves for each core piece for an improved fit. Sections of the hull with tight radii will have more contour grooves than flatter smoother sections. Every core detail is individually CNC cut, and each cut is orientated to generate the desired curvature of the component.

Who is the target market for the Advanced Kits?
Advanced kits are perfect for boatbuilders looking to save time with better fitting kits. They are also perfect for boatbuilders who want to reduce weight and boost performance. Advanced Kits are also a good alternative to thermoformed kits.

What kinds of boats are the Advanced Kits being used on?
Currently, in the U.S., the kits are used on large, sport fishing yachts where a lighter weight results in an increase in speed.In Europe, we work with the large luxury yacht sector, including boats up to 200 feet in length, along with sailboats, high speed yachts, and electric boats where overall boat weight is crucial.

What feedback have you received?
“The kit saved us time in production and the result exceeded our expectations on accuracy and quality,” said Daniel Gustafsson, production manager and one of the owners of Rosattra Boatyard, in Sweden. “The injection process went according to previous tests and the quality was very good. The overall efficiency when it comes to time and economy was enhanced through the use of the ready-made kit.”

Why do you think no one has designed a successful product like the Advanced Kits before?
The technology to design and execute these 3-dimensional kits is not commercially available. Diab’s history in the marine industry and in core kitting led us to develop our own software to provide this solution.

What obstacles arose during the R&D process?
The transfer from a theoretical model into reality is always difficult and it was important to have several customers that were willing to try something completely new so that we could get feedback and make improvements.

What impact do you see the Advanced Kits having on the boating industry?
Because the Advanced Kit creates so many benefits, it can have an impact on several levels. Boatbuilders that rely on their own team to cut core can trust Diab to provide a kit that fits perfectly every time. This saves the shop in space savings, waste management of cut scraps, and frees up that labor resource. Boatbuilders that want to reduce weight can rely on Diab’s Advanced kit to fit tight without grooving every sheet for contour. Boatbuilders demanding perfect cosmetics will see the benefit gained with the tight fit of the Advanced Kit. And finally, boatbuilders with high production times can benefit knowing each Advanced Kit will easily fit right out of the box. The best part is that all of these benefits come with every Advanced Kit.

What plans are in place for the future of Diab?
Diab is continuously innovating in the composite industry.
Throughout its history, Diab has been at the forefront of introducing not only new cores but has also pioneered new concepts that simplify and speed up the sandwich composite production process. Diab’s plan is to continue innovating in the composite industry with core materials, engineering services, R&D, and other added values for the customers, always with sustainability in focus.