Cookson Boats receive CAD (Computer Aided Design) drawings and 3D models from the design offices. Drawings are printed in house for construction purposes and provide an onsite ready reference to design details. Additional in house CAD drawing, 3D modeling, visualizations and simulations are used extensively for tooling design, working drawings, patterns, schematics and on site CNC Computer Numeric Controlled) machining of tooling components .
Cookson Boats have a 40,000 sq ft manufacturing facility located on the North Shore in Auckland.. It is purpose built to include specialized working areas, warehousing, dry fabric storage, pre-preg storage, dangerous goods stores and administration offices.
An on-site 5 Axis CNC Router provides first class accuracy for tooling and mould construction, patterns, and components.
Five purpose built ovens run by natural gas, have thermocouples spread evenly throughout their airspace hardwired into a computer for monitoring and recording the temperature of each thermocouple for each cure cycle.
Autoclave facilities are available for any components up to 500mm in diameter
including rudder, spar, canard, and rig components.
Milling of Keels
Cookson Boats has an association with off site CAD/CAM facilities for three dimensional milling of keels. Access to these facilities guarantees a keel shape reproduced to within fractions of a millimeter in all dimensions.
Cookson Boats has progressed through the generations of composite construction techniques. Initially, modified systems for traditional wet lay up processes with vacuum consolidation were used followed by subsequent development of in-house wet prepreg systems.
Full Epoxy Prepreg Systems
While these earlier systems are still used today, construction of custom high-tech racing yachts combines refined methodologies in the use of a range of epoxy prepregnated standard modulus or high modulus carbon fibres. A low temperature cure epoxy resin system is used in the construction of large components.
Vacuum Resin Infusion
Implementation of Vacuum Resin Infusion for semi production yachts such as the Cookson 50 has demonstrated its benefits in significant cost and weight savings, improved component quality, mechanical performance and working conditions.
For Vacuum Resin Infusion, the foam cores are thermo formed in purpose built moulds.
Quality and Assurance
Linked to Cookson Boats manufacturing processes is their in depth QA process whereby laminate panels are tested and procedures are written for the construction of each component. In association with the engineered technological advances from the Design teams, Cookson Boats is constantly researching and refining composite construction technology. Cookson Boats is driven by the quest for excellence in the construction of high-tech, top performance racing yachts.