Marine Innovation Service

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"WE'RE PASSIONATE ABOUT THE YACHTS WE
BUILD AND WE KNOW THAT THIS PASSION IS
SHARED BY OUR ENTHUSIASTIC OWNERS"

CASE STUDY –

RUSTLER YACHTS LTD

Background

Rustler Yachts Ltd was established in 2000 and moved to their new Ponsharden factory in 2005; however, the first Rustler 36 was built in Falmouth in the early 1980s under the name Orion Marine. In addition to the original 36, Rustler also build 42ft and 44ft ocean cruising yachts and a 24ft day sailer. In development are the 33, 37 and 58 – of which the 33 is the furthest progressed and is the focus of engagement work with the Marine Innovation Service.

Rustler Yachts brand themselves as “passionate about the yachts we build, and we know that this passion is shared by our enthusiastic owners”. A key selling point for them is that “all of our yachts will continue to be hand-built…in a modern environment”, but stress they will “use, where it is right to do so, high technology processes and equipment”.

Rustler Yachts Ltd also own and build the Bowman and Starlight yacht brands.

Objective

Like many established production yards, Rustler predominantly build their yachts using conventional hand lay–up techniques, employing chopped strand mat and woven rovings of E–glass in polyester resin. However, Rustler are keen to adopt more advanced production methodology and develop the capability to build using closed mould processes from vacuum consolidation to resin infusion.

New (to Rustler) technology employed

CNC cutting of body moulds for the plug
Laminating cosmetic wood veneers under clear gelcoat
Resin Infusion

Outcomes of MIS intervention

Loan of vacuum pump – in house training and familiarity with vacuum consolidation
Process consultancy on veneers under clear polyester gelcoat
On going assistance available on resin infusion when reach that stage

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