Shadow Nautics

Construction process

Technology

Technology and Construction Processes

Our construction process is defined by precision, structural integrity, and compliance with the highest marine engineering standards. Utilizing advanced vacuum infusion, CNC-manufactured components, and modular design principles, each vessel is purpose-built and rigorously tested to meet exacting technical, operational, and safety specifications. Whether intended for commercial operations, mission-critical environments, or specialized military applications, every build is fully customizable — shaped by the unique needs, wishes, and vision of each client.

Design Based on Customer Requirements and Software Testing

Our team of experts responsible for design, as well as the preparation of technical documentation and workshop drawings, approaches each customer request with a special focus on individuality and specific needs. Every project begins with a thorough analysis of the customer's requirements in order to create an optimized technical solution that meets the desires and needs of a unique project.

Our design approach includes finding innovative solutions that can be effectively integrated into the construction of vessels, aiming to meet all customer expectations while considering the basic structure and design possibilities. At all times, we strive to achieve a balance between creativity and functionality, resulting in high quality and uniqueness of each vessel we create.

After implementing the necessary changes, we present the results to the customer through computer displays and visualizations, which allows them to review and understand the final appearance of their vessel. These representations ensure that the customer can clearly see what the final executed state will look like, thereby ensuring transparency and increasing trust in our design process.

In addition, we conduct detailed software testing to confirm the functionality and safety of the designed solutions. Our focus on quality ensures that every aspect of the vessel meets industrial standards and customer expectations.

Hull

Preparation of the Mold for Lamination: The first step involves thorough preparation of the mold. The mold is cleaned and coated with a protective layer to ensure easy removal of the final hull.
Application of Gelcoat: Gelcoat is applied to the inner surface of the mold, providing high aesthetics and water repellency in the RAL finish agreed upon with the customer.
Laying the Laminate: After the gelcoat has dried, the laminate is laid according to the laminate plan, which consists of fiberglass and aramid Kevlar. This step is crucial for creating the base structural strength of the hull.
Connection of the Vacuum Infusion: At this stage, a vacuum infusion system is set up to ensure even distribution of resin throughout the laminate. The vacuum creates pressure that helps achieve the desired material density.
Injection of Vinyl Ester Resin: After the laminate is laid, vinyl ester resin is injected to further strengthen the hull layers.
Preparation of the Casting for Longitudinal and Transverse Ribs: The next step involves preparing the surfaces where the longitudinal and transverse ribs will be installed. This ensures that the ribs are properly positioned and well-connected to the hull.
CNC Manufacturing of Transverse and Longitudinal Ribs: The longitudinal and transverse ribs are manufactured precisely using CNC technology, ensuring high accuracy and consistency.
Placement on the Hull: The manufactured elements are carefully placed on the hull in accordance with the workshop documentation for connection to the structure.
Laminating the Installed Ribs: After placement, the ribs are laminated to ensure a strong bond between the ribs and the hull, providing additional hull strength.
Strength Inspection After Casting Using a Barcol Tester: Strength tests are conducted to ensure the quality and resistance of the hull, using a Barcol tester that measures the hardness of the plastic, and test specimens are sent for mechanical properties testing.
Installation of the Deck Support Structure Manufactured on CNC: Finally, the structure that will support the deck is installed and laminated to the hull of the vessel. This structure is also manufactured using CNC technology for precision.
Protection of the Laminate: After the entire process is completed, the hull is protected with topcoat finishes.

We believe that this process must be carried out methodically with the highest degree of control over the production processes to ensure that your vessel will be solid, durable, and optimized for performance at sea.

Deck

Defining the Purpose of the Deck: When designing the deck, it is crucial to consider its intended use and ensure that it meets drainage guidelines in accordance with regulations and standards.
Preparation and Adaptation of the Mold: The mold is prepared to have the appropriate dimensions and shape required by the project, reflecting the future use of the vessel.
The mold is cleaned and coated with a suitable release agent to facilitate the removal of the finished product.
Gelcoat Application: Gelcoat is applied to the interior of the mold. This layer provides a smooth and aesthetically pleasing surface for the deck, with RAL colors for the gelcoat or RAL and technology defined based on customer requests, as well as the type of paint if the vessel is to be painted.
Layering of Laminate: The laminate is applied according to a pre-defined laminate plan. This includes multiple applications of resin and fiberglass to achieve the required strength and resistance.
Removing the Deck from the Mold: After the material has hardened, the deck is carefully removed from the mold, checking all contact point positions with the mold, and strength is measured using a Barcol hardness tester, just like with the hull.
Lamination: The deck is joined to the hull of the vessel through lamination. This lamination is executed on structures positioned on the hull.
Lift Eye: When connecting the deck to the vessel's structure attached to the hull, lift supports are integrated into the structure, providing four strong lifting points (Lift Eye) with a total safe working load (S.W.L.) of 16 tons.
Use of Crystomer Adhesive: In addition to lamination, Crystomer adhesive is used for additional strength at the joint.
Non-Slip Surfaces: Non-slip surfaces are created on the deck to enhance safety during use, in accordance with applicable rules and standards.
Preparations for Deck Equipment: Preparations and pre-cuts are done for the installation of deck equipment such as windows, anchors, railings, handholds, and other elements of deck equipment.
Inspection: After completion, a quality control check is performed to ensure that all elements are aligned and that the deck is functional and aesthetically pleasing.

Superstructure

Description of the Construction

The superstructure consists of an aluminum framework that serves as the foundational structure. Aluminum is chosen for its high corrosion resistance, low weight, and ease of processing.

Profiles are manufactured according to a pre-defined specification to ensure the necessary strength and stability of the superstructure.

Connections between the aluminum profiles are joined by TIG welding and secured to the deck and roof with screws.

Tempered Glass: Tempered glass is installed in the aluminum structure. This glass is selected for its resistance to impact and temperature changes, making it ideal for maritime conditions. At the customer's discretion, the glass can be tinted, and thicknesses and degrees of impact resistance can be specified.
Side Sliding Windows: Side sliding windows are included to enhance ventilation and allow for opening.
Handrails and Rails: Made of AISI316 stainless steel and protected by plastic coating or paint as per customer preference.

Entrance Doors

Stern Wall: The entrance door is located on the stern wall of the superstructure.
Type and Style of the Door: Depending on the project category of the vessel, the type and style of the entrance door can be customized. Possible door types include:
- Sliding doors with an aluminum frame and tempered glass for space-saving and better visibility
- Classic hinged doors
- Reinforced doors for protection against weather conditions or for security purposes
Material: Entrance doors can be made of aluminum, composite materials, or glass, depending on the preferences of the client and specific project requirements.

Roof Structure

The roof is made from a mold created in two parts, consisting of the upper outer element and the inner counter side, which also serves as the ceiling of the roof. Between the two elements, there is insulation and a piping system for ventilation. Handrails, a mast with navigation equipment, and lighting are installed on the roof.

Lift Eye System

The lift eye system for lifting the vessel is integrated into the boat as a mechanism used for safely and efficiently lifting and relocating the vessel onto land or lifting it onto a larger boat, with a load capacity of 16 tons.

Tubes

Depending on the customer's choice, the air chambers—tubes—are made from ORCA Hypalon/Neoprene 1670 DTX material in a RAL finish as per the customer's preference.