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The first part of the process is to come up with an overall rig layout within the rules.  This will assist determining the overall mandrel geometry.

Choosing a one piece mast with no sleeving means that specific patching will be incorporated into the laminate for high load areas, reducing hard points and stress raisers.

Pattern design

We then generate a stiffness profile to suit the mandrel geoetry and mast layout.

Pattern design, optimises the laminate thickness vs stiffness vs toughness.

Patterns go direct from engineering to production floor winding machines, minimising human error.

FEA

With FEA models built to replicate the laminate schedule,  a number of “What if” scenerios can be run to determine various bend profiles.

This provides sailmakers and sailors with an option to choose their preferred stiffness as well as bend characteristics.

Model Vs Actual

Final step in the first article is to confirm actual results vs modelling.

With over 25,000 tubes made, the model predicts the bends within +-1%

Quality control reports show that the bend profiles of all masts are repeatable within +-2%

Rigged mast will be in the boat next week !

Design and build mandrel

One piece mast was chosen to increase stiffness (for a given weight)  as well as create an even bend curve (no flat spots). Over the last two weeks the mandrel was designed and manufactured in house, using SolidWorks and our CNC lathes.

Material selection

Quality performance Japanese fibre used to produce 16′ skiff masts. Using our Instron testing machine, fibre coupon testing is performed to validate carbon suppliers data and quality. There is often a large variation between carbon fibre suppliers.

Quality Control

All tubes and masts produced run through the CST MES (Manufacturing Execution System), this monitors all aspects of production to guarantee quality supply.

Bend testing is completed to confirm actual results vs modelling

A busy lead up into the 2011 J.J Giltinan Championship saw a range of new products being released for the 18ft skiff class. The most significant probably the release of new mast sections for both no.1 and no.2 rigs as well as new rectangular booms. The development included 3D Solidworks design and in house manufacturing of new mandrels. All this was achieved in a very short time frame to allow enough on water testing in time for the championship.

The development was driven by CST’s 18ft skiff guru Chris Dixon and trailed on CST Composites 18ft Skiff skippered by Howie Hamlin. Howie finished the regatta in respectable 5th place showing the potential of the new products with minimal testing. The new masts are an evolution of last year’s design and have been developed to suit the latest sail trends and ever increasing working sail area. The result is substantial increase in stiffness over the 2010 rigs while keeping weight down to a minimum.

The new high modulus 130x55mm rectangular carbon fibre booms are also significantly stiffer than last year’s product. “Increase in mast stiffness called for stiffer booms as well, so going to a rectangular section seemed like the obvious choice. We have now done this for most of our dinghy classes as it has allowed us to maximise the stiffness in the Y axis without the added weight that would have been experienced with the oval section. Rectangular booms have been used in high performance yachts for years, so I guess it was only a matter of time before this development made its impact on the dinghy and skiff arena,” said CST’s GM, Chris Dixon.

In order to bring the weight of some of the skiffs down to minimum, CST also produced a set of intermediate modulus carbon fibre wings for the J.J.Giltinan winning boat Gotta Love It 7. 2kg weight reduction over the conventional standard modulus carbon wings was achieved, while maintaining the same stiffness characteristics.

With the next major regatta being the European Championships, we are confident that with more time on the water CST Composites 18ft skiff will be one of the hot contenders.

Photo: Nathan Outteridge flying the Australian flag after winning the 2011 Moth worlds at Belmont NSW

Nine national and one world championship wins for CST product has been a result of our strong focus on R&D and a close working relationship with some of the leading sailors in their respective classes.

Our congratulation goes to the crew of “Brydens Compensation Lawyers” who bounced back to win the windy 16ft Skiff Nationals sailed from Royal Queensland Yacht Squadron. The team skippered by Lee Knapton used CST’s new carbon fibre rectangular boom, spinnaker pole and fibreglass mast tips in both no1 and no2 rigs.

Current I14 world champions Archie Massey and Dan Wilsdon convincingly won the Australian I14 Championship with a string of first places. They too used the new rectangular boom and a modified configuration HM3 CST mast.

Rohan Nosworthy and crew Neil Tasker dominated the MG14 nationals with the lowest possible score of 7, after scoring a 1st place finish in every heat. They used the newly developed high modulus elliptical mast as did last year’s winner Hugh Tait, who placed 2nd.

Trevor Fay and Nathan Chipchase once again won the Cherub nationals with the CST HM one piece mast while the B14 National Championship was won by current world champions Guy Bancroft and David Grace.

Glen Ashby added yet another Australian Championship crown to his sailing portfolio winning the A-class and Brien Hennessy won the Javelin tittle sailing with crew Andrew Hackett.

Peter V. made a comeback to the NS14 class winning the Australian Championship with Tina Babbage while Nick Craig won the Phantom class in the UK.

Nathan Outteridge was also victorious walking away with the Australian Moth Championship, sailed as a warm up event before the Worlds. He then marched on to win the World Championship as well, sailed in a strong fleet of 113 boats. In fact this was undoubtedly the best quality fleet the Moth class has ever seen. Comprising of a number of World and Olympic champions as well as celebrated Americas Cup and Volvo Ocean Race sailors.

During the past few months CST Composites worked extremely closely with Nathan to develop a range of new masts specifically designed to suit the KA and MSL10 and MSL13 sails. No less that 21 prototype masts were made for the CST Moth Team, refining the bend characteristics to perfection in order to achieve the optimum luff curve match. Nathan also used the new CST rectangular boom which has proven to be stiffer and lighter than last season’s model.

All of the above products will be available as the part of our new 2011 range in the coming weeks.