When it comes to the fairing of a hull and the filler application, the traditional process is not entirely up to date in terms of efficiency and accuracy.
Let's face it, the same process of fairing the hull has been more or less unchanged for more than 90 years. Well, tools have changed and material innovations have changed, but the process itself is more or less unchanged (more on that here in particular).
Finally there is an alternative. With this alternative, many more options have evolved. And they have a side effects that are more than welcome:
To better understand this assumption, let's dive into the process. It starts with a 3D scan of the hull. This process can begin later than when you typically would start the fairing work on the hull. Therefore, all deformations on the hull that arise up to that point can be taken into account. For example, caused by the installation of machines or other work inside or outside. This makes it a more accurate 3D scan than at the beginning.
Based on the 3D scan, a filler map is created to measure the amount of sprayable filler required. This brings the calculations about the material needed to the point. Oh, and just applying sprayable filler by the robot already results in higher efficiency.
Afterwards there is no need to apply a fine filler, as the result of the filler application is already perfect. Another advantage of this process is that it avoids the inclusion of bubbles, which is often the case when applying conventional filler and which leads to rework.
During the filler application the thickness can be controlled exactly. Milling and grinding with force sensors and laser trackers controlled by state of the art CIS compensation intelligence software leads to an even higher accuracy. They follow the exact coordinates from the 3D scan data. A deviation can be excluded, which leads to a reduction in material and weight.
The perfect shape designed by the architects is respected and preserved while optimising the weight within this process.
Less weight means less fuel consumption, which supports the lifecycle of a superyacht in a new way.
The higher accuracy of the above mentioned fairing process leads to a positive impact on the stability of a yacht in the water.
The application and fairing is carried out based on the detailed 3D scan. That 3D scan considers latest deformations caused by other processes during outfitting. The fairing process is supported by laser trackers, force sensors and the CIS compensation intelligence software. All in, it leads to the best results possible.
The 3D scan and the filler map provide a great documentation of the hull. With this documentation future refit processes can be supported in a new way since all areas of the hull have been made visible based on the highest accuracy.