Roger Hill 12m Design takes shape with DuFLEX Composite Panels
Celebrating 10 years – Bonded in Composites
Noosa Cruiser 750 Unveiled
DUFLEX underlies New Generation Charter Cat
NEW Noosa Cruiser Incorporates DuFLEX Strip
DuFLEX the Key to Speed and Stability
ATL Composites has supplied DuFLEX Composite panels and KINETIX high performance epoxy systems for the latest designs from Norman R. Wright & Sons for two new custom designed Pilot Boats for PNG Ports Corporation.
“Siabo” is the first boat to hit the water from Wrights featuring their all-new Extra Long Waterline (XLW Class) design, which offers optimum seakeeping and efficiency in all sea conditions and speeds in excess of 30 knots.
Norman R. Wright & Sons was one of 10 companies to tender for the first of a fleet of 14.2-metre pilot craft.
The DuFLEX Building System was used for the entire vessel construction, including hull shell, frames, bulkheads, deck and superstructure. Panels were supplied as full-sized components and offered significant structural weight savings over infusion and other traditional methods, as well as eliminating the substantial costs associated with moulding.
Working with ATL Composites, Wright’s Naval Architects and Master Tradesmen integrated unique composite construction, combining resin-infused and pressed GRP cored panels with DNV-GL approval.
The design allows for a reduced centre of gravity for superior stability enhancing pilot safety when alongside ships, along with wide, flush, uninterrupted side decks around the entire vessel for optimum safety.
The two new boats are the first in what is expected to be a fleet catering to the growing ports, cargo and liquid natural gas infrastructure in Port Moresby and the 21 other surrounding PNG ports that they service.
PNG Ports Corporation visited Wright’s headquarters at Rivergate Marina & Shipyard, Brisbane and trialled a comparable vessel.
“They were impressed with our 110-year history, our factory and our history of support on similar fleets in North Queensland,” said Tony Riek, Managing Director.
The 14.2-metre design is customised specifically to the needs of PNG Ports Corp designs and is based on an evolution of Wrights’ highly successful Skirmish Class Pilot Boats which draw on over 80 years of Pilot Boat design and building expertise.
“Pilot Boats are a part of our DNA,” explained Tony. “We designed and built our first in 1935 and since then designed and built some of the sturdiest craft seen, in some of the harshest Australian waterways and beyond.
“The quality of our boats means many are still in continuous service after decades of operation. There are Pilot Boats still in operation which we built in 1993. We have a team of highly skilled and qualified naval architects and boat builders using the latest technology, processes and high-tech materials.”
ATL Composites engineered the vessel to meet DNV-GL: 1A HSLC R2 CREW, and worked closely with Adam Evripidou, Tony Riek and the Wrights’ team on developing and optimising build techniques.
DuFLEX Composite Panels reduce construction time and optimise structural weight in the production of light weight composite structures. Using DuFlex panels in boat construction avoids time-consuming laminating, coring and vacuum bagging steps normally required to fabricate high performance composites, and material waste, labour and tooling costs are greatly reduced
More information at www.duflex.com.au
Video of the boat in action: https://www.youtube.com/watch?v=g-ZpYgBPZ5A
Light, strong, fast and versatile, the Noosa 7 is turning heads and winning hearts.
Pre-Fab Perfection
Feature-filled power cat AYANA breaks New Ground in Charter
The latest Roger Hill-designed vessel, the 14-metre power catamaran called “AYANA”, has emerged from production at Noosa Marine and is now stored at The Boat Works, awaiting delivery to her discerning owners who plan to cruise from the Gold Coast back to their home waters of WA.
The fully-custom designed and built power cat is replete with unique features befitting a luxurious liveaboard vessel. With her planing hull, AYANA was built to survey with the intention of offering day charters cruising Rottnest, Margaret River and the Swan River.
As Julian Griffiths, Director at Noosa Marine explains: “AYANA weighs around 12.8 tonnes and has loads of extras. Her owner is an experienced boatie and wanted the works.”
AYANA is a spacious three-cabin multihull conceived for day charter, with a massive, versatile cockpit for entertaining or angling, which flows into the large saloon, also decked out for socialising with dinette, galley, AV and large windows for panoramic views. The enclosed flybridge features the helm and an L-shaped lounge and dining table, while the aft deck is fitted with a davit for the vessel’s tender.
Designer Roger Hill said the list of ‘must haves’ was daunting for him as a designer and for the team at Noosa Marine.
“From my perspective, the challenges involved weight control more than anything else. AYANA is a 14-metre superyacht. It probably has more fridges and freezers than any other 14-metre afloat!
“There is no such thing as a boat that is not some form of resolved compromise. But this boat is probably as close to what the owners would say has everything they want in a 14-metre package and from my point of view the biggest compromise will be the performance of the planing hull, which will still achieve around 28 knots.”
According to Roger, building to survey requires more structural material and more safety details, which results in extra weight and additional costs of around 20 percent.
“This boat was built to the highest standard of survey in Australia so it is at the top end of the spectrum for cost and compliance,” adds Roger.
From briefing to completion, construction took just 13 months. The Noosa Marine production team comprised Julian, Max, two apprentices and a labourer.
Key to their efficiency was the use of the pre-cut DuFLEX panel system from ATL Composites.
Other DuFlex panels in AYANA were cored with Divinycell’s H80, an industry standard for marine projects and ATL’s Featherlight Marine Interior panels combined Divinycell H60 core with 600gm double bias laminates.
All components for the build, from temporary framing to structural hull sections, bulkheads through to the interior fit-out for AYANA were digitised from design files and nested to optimise the number of panels required for the project that were with ATL’s proprietary Z-Joint for joining and subsequent quick assembly.
“DuFLEX is incredible for saving time and reducing weight onboard,” Julian attests. “DuFlex offers builders a very high-quality panel and very precise accuracy, and for the client, an assurance of structural integrity.”
Roger agrees, stating: “Using the ATL Composites DuFlex panel system is a great way to build a boat particularly when it is embraced so well by this builder. Personally, I really appreciate the service and help that the team at ATL offers me as a designer. Their back-up and support are great.”
Celebrating 40 years of Innovation in Composites
ATL Composites is celebrating 40 years of operations, supplying innovative coposite products to the marine, automotive, industrial and construction industries in Australia and around the world.
Paying tribute to the vision of founder, Arnie Duckworth, who established the business in New Zealand in 1977, and the efforts, expertise and ingenuity contributed by ATL staff over the decades, Director Nicholas Cossich said “Without question, 40 years would have been impossible without the dedication, hard work and skill of our past and present talented staff who are very much looking forward to the future challenges and opportunities that our dynamic industry always presents.”
Mr Cossich also honoured the support and collaboration of ATL’s valued clients. “Success to date would not have been achieved without the firm support of our valued clients, distributors, dealers, colleagues, engineers, designers and naval architects to whom we are exceedingly grateful.”
The origins of the company are proudly in boat building, in the late 70s when Mr Duckworth, an avid sailor, relocated to NZ after a period working for the legendary Gougeon Brothers Inc in the US.
The Gougeons had developed the WEST SYSTEM epoxy system, that was revolutionising timber boat construction, by stabilising the moisture content of the wood. Back in the boat building powerhouse of NZ, Mr Duckworth observed a market for epoxy products to supply to the burgeoning marine industry, manufacturing WEST SYSTEM epoxy products under licence to Gougeon Brothers for the Asia Pacific region.
The decade of the 2000s were marked by an expanding market for multihull construction by both professional and amateur builders, whose designs were specified around the DuFLEX Building System, and the ATL used its knowledge and experience of composite materials to diversify into other markets where there is a demand for lighter, stronger, stiffer, more durable structures including automotive, architectural and surfing/sporting equipment and transportation applications.
An outstanding achievement in 2012 was the development of a range of unique epoxy systems with extremely high compressive strength and toughness for the construction of James Cameron’s Deep Sea Challenger, a 7.3-metre deep diving submersible that made a record breaking 11 kilometre descent to the bottom of the Mariana Trench.A success which in essence thoroughly vindicated ATL’s certifications to ISO9001 and approvals under DNV-GL for delivering world-class product quality and performance.
“Enduring and close partnerships with leading International manufacturers including DIAB Group Sweden , Hawkeye Industries USA, Airtech Inc USA, and of course our very good friends at WEST SYSTEM Inc, USA, have been key to strengthening our position in existing markets, and expansion into emerging composite industries,” said Nicholas.
“We are also fortunate to be very well supported by a long established and extensive Distribution/Dealer network in every State and Territory of Australia and also throughout Asia in Thailand, Japan, Singapore, Vietnam, Malaysia, Indonesia, Philippines, Hong Kong, Papua New Guinea and Korea.”
Since 2012, ATL has enjoyed a fruitful joint venture partnership with MuH von der Linden of Wesel, Germany forming, vdL Composites GmbH to manufacture DuFLEX panels for the European market. During the successful showing at METS, Amsterdam in 2019, vdL appointed Distributors in Italy, Turkey and France to represent the DuFLEX and Featherlight composite panels in their regions.
ATL started 2020 with new products, a vision for the next decade and a commitment to build on the camaraderie and close bonds among their network of customers and colleagues worldwide.
Inga von der Linden, Director at vdL Composites, Germany sent her congratulations to ATL Composites for 40 years of innovation and excellence.
“We have been working together more than 30 years, since 2012 as distributor of DuFLEX and DuraKore panels and also for many years prior as colleagues and friends in the composite industry selling many similar product lines.
“We have had a shared stand at METS Amsterdam, also sharing houseboats, talking to each other monthly via Skype and seeing us at other industry events. That has made us much more than business partners. I love working with Lorraine and Nick and I wish for them many more successful years ahead.”
Ian Wright, third generation boat builder at Norman R. Wright & Sons, which itself commemorated 110 years in business, has been collaborating with ATL for around 30 years.
“There are almost too many yachts over the past three decades to mention by name,” said Ian.
“We met Arnie in 1982 and started working with ATL in 1987. ATL has always offered excellent support and service, especially on the technical side,” he recounted.
“In the past 15 years, they have contributed to the engineering on projects and we have been very grateful for their expertise.
“We have become extremely close, bonded by our mutual love of boats, cars, construction and aeronautical engineering. My son, an aerospace engineer, actually did work experience at ATL. They also helped build him a billycart when he was six years old.
“ATL supplied material and advice when I was building my family home at Wynnum – a green composite house we call the ‘eco-casa’. Lorraine and Nick are a great duo with exceptional skills and very complementary talents. We congratulate them on their 40-year milestone and all the best for many, many more.”
Tony Grainger, founder of Grainger Designs said “We’ve been with ATL Composites almost since the inception. From the 8m trimaran Dux Nuts (1987) through to our latest all carbon 42-foot custom trimaran Venom, and a host of catamaran and trimaran projects in between”.
“ATL have been with us on the journey with materials, state of the art laminating technology, DuFlex kits for our cruising cats, and engineering support.”
He continued: “There’s no digging needed to discover the success of ATL’s longevity. It’s cultural. The same faces are there year after year armed with technical know-how and a welcoming smile, whatever the questions. Congratulations and thanks to all the crew at ATL; and here’s hoping you guys are around for a lot more anniversaries.”
Jake Holloway, Product Manager at Shapers Australia, which supplies surfboard manufacturing products to leading surfboard shapers around the globe, was impressed with “ATL’s big 4-0”.
“That is an impressive innings to say the least, for any company in any industry,” he said. “In a highly competitive and rapidly changing environment the ability to maintain such a high level of product quality, customer service and innovation rings accolades to ATL Composites.
“What our company (Shapers Australia) really appreciate and find highly motivating is the relationship we have established with ATL. The culture of ATL is to work with customers as a team, a genuine partnership arrangement.
“It is through this partnership that ATL and Shapers Australia have been able to combine critical knowledge, share sensitive information and lead the world in the field of specialised epoxy solutions for the Surf Industry. The distribution achieved has been on a global scale and importantly the channels of communication are always open, always flowing and always looking towards the future. This mutual success is achieved through a partnership built on mutual trust and respect.
“From all the team at Shapers to all the team at ATL, Happy Birthday and a whopping big Thank you. Please raise your glasses and here’s to many great years ahead!”
Marinesports International in Victoria was among the original WEST SYSTEM Distributors appointed in Victoria. Director Andrew Morrison sent his best wishes for ATL’s milestone.
“We established WEST SYSTEM with leading yacht chandleries and boat builders and in more recent times, several quality furniture manufacturers have come to realise the many benefits of using WEST SYSTEM products as a glue and for sealing timber.
“Over the past 40 years ATL Composites, under the guidance of Nicholas Cossich, Lorraine Murray and their team, have grown a reputation for excellent customer service offering quality products with technical support. We wish them every success for the future.”
Mr Cossich said the team at ATL was grateful for their customers’ loyalty and enthusiasm for ATL’s extensive range of products, commenting on their valuable input which has spurred product development and enhancements.
He said ATL is energised by attaining the 40-year marker and has no intention of resting on their laurels.
“We will continue to push the boundaries of material performance through our active research and development programs, and are looking to expand and improve our materials and technical proficiency in numerous aspects of cosmetic finishing, thermal ranges, fire-resistance and sustainability.
“Important new growth markets include defence, automotive, architectural and civil which are now leveraging our solid foundation of expertise and technology developed over decades in our key marine business.
“Our significant, long-standing international and domestic supplier relationships will continue to allow us to complement our own product ranges by offering world leading advanced composite materials to the Australasian market.”