01Step 1: Hull Fabrication
Aluminum hulls start as marine-grade alloy panels cut by CNC to 0.1 mm tolerance, then rolled and welded into the hull form. Weld seam integrity is checked at dedicated stations before any panel moves downstream.
Fiberglass hulls are molded instead: a gelcoated mold receives layers of glass and resin in a controlled layup schedule, then cures before demolding. The mold defines the finish — which is why fiberglass accepts gelcoat colors so well.
02Step 2: Transom, Stringers and Deck
The transom carries the outboard, so it is reinforced to match the rated engine power of each model. Stringers stiffen the hull, and the deck — self-draining on professional models — is fitted with fuel-tank space, cable routing and drainage planned from the drawings.
This is also where lifting points, cleats and rubbing strakes are positioned. Their placement is specified per model and verified against the frozen specification later in QC.
03Step 3: Tube Collar Fabrication
The collar is built from coated fabric — PVC or CSM (Hypalon®) — cut into panels per pattern. Panels are welded into tube segments, segments into full tubes with internal baffles dividing them into separate air chambers.
Welding is done by high-frequency (RF) machines for PVC or thermal welding depending on fabric, with temperature, pressure and dwell time logged per production run. Each chamber gets a valve.
04Step 4: Collar-to-Hull Assembly
The collar mounts to the hull along its full perimeter — bonded and mechanically fastened so loads transfer cleanly between tube and hull. Alignment matters: an uneven collar changes handling and accelerates wear on the contact line.
Consoles, seats, steering systems and other fittings are installed after the collar, following the model layout agreed on the approved sample.
05Step 5: Testing, QC and Documentation
Every collar set is pressure tested — chambers hold 0.35 bar over 24 hours, and any drop above 0.02 bar rejects the boat. Finished boats pass seven inspection gates (Node 01–07) with a 120-point assembly checklist, and serial-level records keep each hull traceable for 10 years.
For EU-bound models, CE documentation under the Recreational Craft Directive 2013/53/EU accompanies the build. A factory that can show you this pipeline — cutting, welding, assembly, test logs — is a factory you can audit.