Bringing high-performance F1 technology to superyacht Tender
Leading advanced engineering company Dash has worked with Falcon Tenders to develop and produce a carbon fibre roof.
With its engineering design and composites expertise, Dash delivered a completed product that was 75 per cent lighter than the required target. This was achieved with the utilisation of a new high-performance composite foam, ROHACRYL®, which has been developed specifically for the marine sector by EVONIK, a leading supplier of high-performance foams to Formula 1 and aerospace.
Falcon Tenders is a world-leading builder of bespoke superyacht tenders, crafting limousines and launches for discerning customers around the world. Inspired by a history of powerboat racing, many of its vessels embrace high-performance design and engineering. In a recent project, they encountered a unique set of design and manufacturing challenges that led them to long-term collaborator, Dash.
Performance design & production
Dash was provided with a design ‘A surface’ and some basic load requirements. The primary challenge was to safely integrate and support the 120 kilograms of glass that would provide occupants with panoramic views. Equally, the bespoke and coachbuilt nature of Falcon’s projects meant that the finish and function would need to be exceptional. An accelerated timescale drew upon Dash’s extensive motorsport expertise in delivering high-performance and cost-effective solutions.
Dash successfully delivered the complete solution in just six weeks, covering in-house engineering design, simulation, tooling, and production. This included a detailed design of the laminate and carbon fibre layup, maximising stiffness and strength while minimising weight.
World-first marine application
This project is the first-ever marine application of the innovative new material ROHACRYL®, which was provided by EMKAY, the official UK distribution partner of EVONIK. Having used similar technology to manufacture numerous components in motorsport, Dash’s engineers were eager to utilise ROHACRYL® in a high-performance marine application.
Tim Robathan, Chairman at Dash, commented: “This project has demonstrated the potential for technology and skill transfer from motorsport to marine, particularly with the groundbreaking use of ROHACRYL®. It was also a demonstration of our team’s ability to deliver solutions to complex design challenges – including manufacturing – in accelerated timescales. We are excited about future possibilities for this technology in the marine industry, such as racing yachts and performance vessels. We look forward to our continued collaboration with Falcon Tenders.”
Mark Pascoe, co-founder and CEO at Falcon, added: “Not only did Dash complete the entire project in just six weeks, but they also exceeded our expectations for performance, lightness, function, and finish. At 75 per cent lighter than our original target, it enabled us to use resources more efficiently in other areas of the build. Importantly, it perfectly matches the vessel, and we are thrilled with the result.”
Steven King, CEO at EMKAY, also added ‘’I am pleased to see ROHACRYL® prove why it will become the ultra-premium choice for luxury boat builders who wish to focus on weight saving and performance. ROHACRYL® also ensures they are taking environmental impact seriously, as the recyclable raw material base of ROHACRYL® offers a low carbon footprint and a clean end-of-life solution.”
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