From small and seemingly insignificant items to major structures, each part is reviewed to ensure its fitness for purpose and the appropriate design and engineering methods are implemented. Designs are frequently taken from a previous project, reviewed and enhanced, or they begin life as a conceptual sketch. After this, the component is either drawn up as a two-dimensional CAD drawing, or in the case of more complex, high value or less dimensionally tolerant structures, as a three-dimensional solid model. This particular example shows the original concept sketch of the rotating bow pole for our IMOCA 60 Hexagon and the finished product which included a gennaker tack lock that OC developed for the pole end. Depending on the materials, complexity and type of part, engineering calculations are either completed by hand, via spreadsheet for the dozens of ‘standard’ components we have in our library and/or checked by FEA in house or by independent consultants.

Designing custom components in 3D ensures those parts are fully optimised in terms of geometry, ensures their weight is accurately accounted for and reduces the manufacturing costs, particularly of multiple parts. An excellent example of this is the original 2D design of a ballast valve and scoop for an open 60 that was custom designed because off the shelf versions were heavy, resulted in poor (slow) flow and could not be dismantled at sea to clear blockages. The basic valve design was improved such that two tanks fore and aft in the yacht can be filled/emptied using one component saving the weight of two valves and halving the number of holes in the hull. The new design was created as a 3D solid model for CNC production purposes and the latest versions now have an even lighter composite body. Five different sized valves have been manufactured for Open 40’, 50’, 60’, Volvo 70 and maxi designs. The design is available under licence or can supplied as a finished and inspected product.

A strength of our office is a history of delivering complex projects that work, completed on time and to budget. Our ability to deliver comes from our background as boatbuilders, project managers, but also as mechanical engineers and designers of IMOCA 60s. By their very nature 60s include complex mechanical systems and hardware such as, canting keels and deploy systems for highly loaded foils. Our competence in mechanical design allows us to innovative in-house solutions that help to drive the rest of the design space forward and produce a better overall design. From Acciona, the first emissions free IMOCA 60 to the hybrid drive on our 25m polar motor-sailer, OC’s appliance of current and future technology leads to better solutions. We’ve taken on projects such as a three mast 75m schooner confident we can complete the mission. Our history means we always have performance and reliability in mind, whether on the race course or for example looking to reduce vibration or improve air movement in a large yacht. We really never do forget the maxim; simplicate and add more lightness.