Improved productivity : Innovative production methods for a redesigned boat hull

Abstract: With the world shifting towards ever more sustainable practices and products, the maritime industry is expected to do the same. X Shore has found itself well-established in the new and niche industry of electric boats. Currently, the demand for their boats is remarkably high, and a natural transition towards automated production is required to fulfil this demand. Today the boats are mainly handmade, which is both time-consuming and costly. The goal of the project is to determine which production methods are viable for the company and what changes to their existing product will be required to successfully implement these production methods. First, by researching which methods are available on the market, eight major alternatives were noted. After briefly examining each method, they were limited to four viable options: ATL, AFP, Hybrid ATL and AFP, and Diaphragm moulding. These four methods were then compared against each other, which left AFP and Diaphragm moulding as the most viable alternatives now. With the most suitable production methods determined, it was then time to determine what modifications needed to take place for their existing product to function with these methods. For AFP, all tapered surfaces needed to be removed. Complex designs and rounded surfaces with radiuses below 30 mm also needed to be modified. For Diaphragm moulding, tapered surfaces could remain, but complex designs and radiuses below 40 mm required modifications. After further analysing the existing models and discussing with experts in the field of carbon fibre production, a conclusion was made that likely a full redesign of the hull - rather than modifying the existing one - was a better solution for the company when solely looking at producibility.