Composite repairs and supply of composite components

Part of Team Malizia for the winter refit and foil upgrade on Imoca 60 Seaexplorer - Yacht Club de Monaco

I managed the day to day operations of the lamination department, with a staff compliment of 35 composite technicians which included five mast building lines, a cutting room and components lamination. Highlights in this role include overseeing the lamination of masts and booms for Ker 40+ and 46+ yachts, making use of HM and UHM prepreg and overseeing the lamination of the RP90, SWS96#01 and 105#01 masts and booms for Southern Wind Shipyard.Further achievements include the following:The upgrade of vacuum consumables and debulk procedures, resulting in shorter mast laminating times and improved laminate quality.Overseeing the design and commissioning of an autoclave operator board to simplify autoclave operation and to enable the data logging of vacuum and bladder pressures during the cure of prepreg composite yacht spars.

As process engineer my responsibilities included the design for manufacture of new mast tooling, design of mast construction jigs and fixtures, development of standard operating procedures and the installation of new equipment and machinery. Highlights in this position include;- Project manager for the installation of a 60 cubic metre, 160kVA composite curing autoclave.- Development of an in-house NDT strategy for evaluating the quality of new built carbon fibre mast tubes.- Overseeing the installation of a 300kVA diesel generator and a 50kVA rotary vane compressor.

I led a team of 12 composite technicians during the simultaneous build of two Reichel Pugh 37, advanced composite, racing yachts. Responsible for all aspects of production, operations, procurement and administration. Further responsibilities included the following component and process designs: - Design and manufacturing of a 2500kg capacity lead casting furnace and keel bulb tooling - In-house manufacturing of carbon fibre bowsprits, steering wheels and stanchions - Design and manufacturing of sliding companionway hatch tooling and steering pedestal - Drivetrain and systems installation - Design of cradle structures

Twelve month internship at Southern Wind Shipyard as part of National Diploma course in Mechanical Engineering.