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created for aerodynamically and structurally optimal sizes and shapes, not just inherited legacy shapes created out of tooling from previous projects. An example of this is in a 52ft


catamaran project for an Australian client that is currently under build at McConaghy. Justice explains how the MC1 Spars team has found a solution that not only meets the performance-safety balance for the spar package but also comes at areasonable cost. ‘High-modulus carbon is about


20 per cent lighter than standard modulus carbon but is about two and a half times more expensive,’ he says. ‘So to keep the costs down but still achieve our structural goals we devised a laminate schedule that features high-modulus carbon in the important 0° axis but standard modulus in the 45° and 90° axis. It almost gets the full weight-saving benefit of a full, high-modulus rig while keeping the robustness of standard modulus in the off-axis.’ Laminate integrity relies not only


on clever design but also on using the bestmaterials in carefully controlled fabrication processes.MC1 Spars sources its pre-preg carbon from reliable suppliers, such as Delta and Gurit, where there is strict control and consistency of the carbon-resin content, with curing done in one of three autoclaves which, at lengths of six, 13 and 40metres, can reach 120°C at 5.5 bars of pressure to achieve perfect, void-free laminates. This process creates a high


degree of control and stability in part sizing and dimensions that also has benefits where it can really count: when spars are fabricated in sections so they can be shipped and assembled on site at commissioning locations, such as those in new venues in Asia. This delicate and


Above left: MC1’s spar laminates are built on female carbon tooling. Above right: SolidWorks 3D modelling delivers an impeccable fit between rig design and yacht design, ensuring optimal performance and precision


critical process will be assisted by MC1 Spars’ new service and support network. The same high level of attention


to quality laminates will soon be applied to furling booms and sail control components, where it’s just as important as it is for masts and conventional booms. Partnering with KZ Marine, MC1


Spars is now able to offer a wide range of booms with in-boom furling, a safe and effective sailhandling solution that is popular with cruisers and performance-cruisers alike. ‘Unlike the conventional heavy


alloy spars often seen in this genre, our version is a game-changer in terms of reliability, light weight and performance,’ Justice says. ‘It’s the only one in the industry constructed from pre-preg carbon and Nomex core materials that are autoclave- cured at 5.5 bars.’ This new product line will include


hydraulic and electric options which can be configured for boats ranging from 40ft to 115ft in length, and thus attractive to a potentially wide market ranging from coastal cruisers to superyachts. ‘We’re excited about this


particular expansion in our product line,’ says Justice, ‘not only because of its wide appeal but because with our efficient design and production process we can carefully control the timelines and costs so that there is a realistic and affordable base price list available based on standard sizing. This makes it easier for production boatbuilders to sell as an upgrade option in their product lines, as well as those wishing to retro-fit and improve their existing yachts. Our team can custom-build these booms for even larger yachts, but the pricing will be commensurate to the size and complexity.’ MC1 Spars is taking an even


further step into the cruising world by devising a brochure that outlines a base price structure for cruising spars of 40, 50 or 60ft with the mast, rigging and box boom priced individually. ‘This idea is to make a broader


appeal to a new base of customers who have just assumed carbon spars are all customised and out of reach in price,’ says Justice. ‘We are confident of our production efficiencies, quality controls and ability to deliver to a world-wide market that will respond well to these offers.’ Lastly, MC1 plans to expand on


its ongoing supply of high-quality carbon component parts for raceboats such as rudders and foils, steering wheels, pedestals and retractable propulsion units – to now include sail-related components. These will include items such as carbon headboards, carbon clew boards and batten technologies where there is a benefit not just in light weight but in durability and strength as well. ‘We’re getting feedback that a


trend in deteriorating quality of stainless steel is resulting in not just rusting of headboard and clew boards, but it can accelerate galvanic corrosion due to the carbon content in sails,’ says Justice. ‘Titanium is a viable alternative but expensive to machine, so we thought high-quality carbon laminates would be perfect to help solve this problem.’ With their proven expertise in


bespoke structural laminates and high efficiencies in production, Justice sees battens as also being another fertile ground for MC1Spars’ expansion into providing high-quality and cost-effective products to performance sailing and cruising. www.mc1spars.com


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