32 March 2016 D E S I G N Sophisticated software produces AC455 sailing in Bermuda SMOOTH SAILING Over time, the craft of boatbuilding and the boats themselves continually evolve to take maximum advantage of the tools and materials available. Marine manufacturing resources today include computer-driven 5-axis machine tools and strong, light weight carbon-fibre composites. Even the most skilled boat builder of the past would find it impossible to match the complexity, accuracy, performance and reliability of boat components created through digital part design, CNC machining capabilities, user-friendly CAM software, and advanced construction materials. Among the best examples of modern boatbuilding are America’s Cup-winning sailing yachts. These high-tech vessels can reach peak speeds of 40 knots (76km/hr, 46 mph), as much or more than two times the speed of the wind that propels them. Core Builders Composites (CBC) of Warkworth, NZ, represents the state-of-the-art in composite component manufacturing. Established in Ventura, California in 2001, CBC constructed all of Oracle Team USA’s racing yachts including USA 17, the 90’ x 90’ trimaran that won the 33rd America’s Cup in February 2010, and components for the AC72 wing-sail catamaran that retained the Cup in 2013. After the 2010 victory, CBC founders Tim Smyth and Mark Turner brought the company and its team of expert composite fabricators to their native New Zealand. CBC machines high-precision 2D and 3D forms, produces precision moulds, plugs, and direct female tools and carries out CAD design. The company undertakes bespoke composite manufacture and metal machining to customer specifications, and works with customers to develop cost-effective manufacturing solutions for marine, industrial and infrastructure projects. Large envelope manufacturing technology and extreme precision are integral to composites tooling, prototyping, and part production. CBC’s Warkworth facility has three dedicated CNC machine tools capable of machining composites to an overall surface accuracy of 0.2mm. The premier machine is a CMS Poseidon 5-axis CNC high-speed gantry machining centre with a workpiece capacity of 18m x 6.2m x 3m. The machine is the largest of its type in New Zealand and one of the largest in Australasia overall. It is capable of directmachining large-scale shapes and objects such as hulls, architectural features, or wind turbine blades and
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