Updated: Jul 24
DUBAI, 25.5.2021. We finished the big moulds of the AEOLOS P30: Hull, Deck, Deckhouse, Keel, Rudder, Bowsprit. Here´s the mould making story.
The design of the Aeolos P30 base boat was finished in March 2021, we added many more nice details and high quality fittings, like beautiful, individual carbon hatches, hidden tacklines, textile halyard clutches, improved bowsprit, bathing platform, Karver winches and much more. The Aeolos P30 is fully 3D designed with Rhino and Solidworks. Due to the fact all data is available in 3D, we ware able to optimize the boat before we started production:
- CFD-Analysis: Computational fluid dynamics (CFD) for hull speed optimization
- Rating-Analysis based on ORC
- Sail analysis with SailPack-KFSI, Fluid Structure Interaction calculation
- Structural calculation with Femap nastran for FE By the way: We offer a virtual boat tour by zoom. If you are interested, make an appointment via: email@example.com.
To bring the boat into reality we are using robotic milling technology to minimize the tolerances. To steer the final boat production and record the quality management process we use our own Aeolos Production Managment database software.
The boat will be produced with prepregs, which means the boat will be stronger, lighter with less tolerances... like a Formula 1 car, but baked in a 15m x 5m x 3m oven. UAE based prepreg manufacturer NOTUS is supporting us with 200g twill, 400g Biax and 400g unidirectional carbon. https://www.notuscomposites.com/
We don´t use gelcoat, we use much lighter PU Yacht paint developed by ALEXSEAL. https://www.alexseal.com/
Producing a boat at the moment is quite challenging, but also exciting. In April 2021 80% of all people in the UAE are vaccinated, but Corona is still present. Some containers with materials are delayed thanks the blocked Suez channel. But we find solutions and we are working hard ...
Aeolos P30 mould construction: The hull mould is divided into 2 parts because of the negative bow and the chines. The deck mould is one piece, the deck is added after gluing in the stongback. These moulds are milled with a Kuka robot on a 15m track. First the surface is roughly covered with styrofoam and firmer foam, then the block is coated, polished and we make the negative production moulds. In parallel, the hatches and other small parts are milled on a smaller CNC machine.
The milling of the first half of Aeolos P30 hull. First very rough milling, then finer and finer. Several days continuous work. After the milling we are reinforced the foam block and adding a layer of special fine milling material. Then the whole thing will be milled again ... very nice and with less than 1 millimeter tolerance.
Now the hull has some shape but less than the final block... it will become thicker again: next step is filling the gaps and glass/epoxy on the whole thing.
The milled block of the first half of the AP30. Now it´s possible to see the shape properly.
Good Progress: Deck milling finished. Hull becomes prepared for painting and polishing.
First block polished. Unfortunatley we had some issues with corona, all healty now, but same days delay in production.
After milling all the 1:1 parts we are producing a 1:10 version. If you are interested in a full Carbon Radio Controlled boat, please contact us. Check this video, too: https://www.youtube.com/watch?v=UGGlztypwRg&list=PL237DF880A59220EB
The rudder is in milling process. All parts of the AEOLOS P30 are milled now.
Applying tooling paste ton the deckhouse.
Reinforcements for the rudder moulds. The rudder will be produced with high pressure.
The deck block has got the last sanding and will be polished soon.
The hull mould got the steel frame attached. All big moulds will get wheels for easy handling. https://www.aeoloscomposites.com/aeolos-p30-racer
The port hull mould is finished.
Deck block is polished.
Starboard hull milling.
Polished deck mould.
Igor is checking his bowsprit design.
strong rudder moulds
The rudder is an important foil and gives a big advantage upwind.
Deckhouse mould. Protects the cockpit from spray and water.
Starbord hull with steel frame.
Starbord hull mould lifting.
No damages :-)
Looks smooth. We screw the two halfs of the hull mould together, then we laminate. Means the hull is one piece. For demoulding we open the screws.
The last mould of the big mould set!
The hull block. The hull has less surface compared to conventional designs. Means less weight. More strength. Better aerodynamics. https://www.aeoloscomposites.com/aeolos-p30-speed
The final hull mould. Most of the part of the hull ist one strong piece of continuous fiber. That´s one of the reasons for the low weight and high strength. https://www.aeoloscomposites.com/aeolos-p30-strength
The Aeolos P30 Video-Short-Story: https://www.youtube.com/watch?v=FK-d9R9MvBU
More information here:
The Aeolos P30 Video-Short-Story: