Commissioned in 2006, the Maltese Falcon remains one of the largest privately-owned sailing yachts in the world at 88 m (289 ft). The ship was designed with an unmistakeable and highly advanced DynaRig, built in carbon fibre. Morley technicians produced the 18 carbon fibre trusses for the rotating rigging. Split into 36 halves, the mouldings had detailed plants fitted to them to accommodate winches, strong points, access doors and internal bulkheads.
Morley also infused around 170 internal bulkheads and structural members as flat panel parts before being bonded into the trusses themselves. Full size CAD plots with the individual bulkheads and internal components nested plot were laid on a table and panels were infused over the top. This allowed cut lines, data and bonding lines to be transferred to the products which reduced processing times considerably.
Assemblies were completed on budget, packaged and delivered to Turkey. The ship has 15 square sails (five per mast), stored inside the rotating carbon fibre masts.
At part of an extensive refit at Pendennis Shipyard, we replaced the existing superstructure of the 138 ft, 1920’s motor vessel, Fair Lady with engineered e-glass and carbon panels. The considerable weight-saving was necessary for Fair Lady to meet today’s stringent MCA requirements. To this end, the bridge deckhouse sides were constructed using carbon fibre, while the working deck, working deck furniture, bridge deck, bridge deckhouse, deck heads and side decks were completed in e-glass/epoxy sections (some over 13m long). All parts were manufactured using resin infusion techniques with all panels infused in a single process.
In the superyacht Sarafsa we incorporated our real veneer finishes at the point of manufacture of the transom installation ensuring the bond to the substrate was of the highest quality. Our unique process ensures there is no moisture whatsoever present in the wood resulting in a laminate finish that will never yellow from moisture trapped within or soaked up from a fastening. Our laminates are infused with degassed epoxy resin resulting in a dramatically improved surface finish.
Commissioned by the National Trust, this Marcos Lutyens and Alessandro Marianantoni sculpture is titled C02morrow. Brought to life by Morley Composites, the impressive installation is made from carbon fibre and aluminium and contains LEDs to ensure it retains its impact at night.
Co2morrow was constructed from infused carbon. Each pentagonal hexacontahedron was clear-coated with the outer face finished in pearlescent topcoat. The structure measured 4.9m x 6m and was mounted on the Royal Academy building in central London. See more here.
We were contracted to manufacture and fit two composite pools on a superyacht. By infusing a well-engineered laminate, Morley technicians managed to reduce the empty pool weight by nearly two tonnes from the original engineering proposal.
Tooling and production consultancy to steel fabrication shipyard for the production of four fishery protection vessels in GRP. We provided training and expertise to this African yard which was new to these materials and processes. Our role included on-site management to create the production moulds and guidance on material selection and writing of a training manual.
We engineered and built a 4m x 3.5m bimini in FRP sandwich using epoxy e-glass with Corecell core for this Pendennis newbuild project. The structural brief included 400kg total load uniformly distributed and with a design factor wind loading of 70knots.
Contracted by a large UK shipyard, we constructed a set of substantial louvres for engine room ventilation out of infused carbon e-glass. Working closely with the shipyard's own engineers we ensured the finished product met design requirements including wind loading factors.
Assisting Boat Developments Ltd, we supplied female tooling and two sets of canards painted and ready for shipping to a tight schedule. The build required a complicated layup using pre preg, foam core and resin infusion. The project was managed using build sheets and laminate assurance checksheets to document laminate quality.
The requirement was for a lightweight paserelle engineered to take a half tonne loading. Working with our composite engineer, they were designed to Lloyds Rule for Composite Construction and manufactured in infused, cored e-glass.
Assisting Boat Developments Ltd, we dealt with damage in the hull after NDA checking to establish the extent of damage, we worked closely to a laminate schedule provided by the designers.