sail-world.com
 
 
News Home Cruising Photo Gallery Video Gallery

 

Sail-World.com : America's Cup: First images of the AC45 construction at Warkworth

America's Cup: First images of the AC45 construction at Warkworth

'AC45 male mould under construction - BMW Oracle Racing building facility - Warkworth'    © Richard Gladwell    Click Here to view large photo

BMW Oracle Racing look to be set to put the sleepy northern Auckland town of Warkworth on the technology map with the establishment of a new hi-tech boatbuilding facility that will employ between 50-70 people.

The new facility to be known as Core Composites is off to a flying start with the production of the new America's Cup 45 class of catamaran, but will be also supplying to other boat builders and users of composite components.

Based in the old Rodney and Waitemata Times production facility, previously a major employer in the area, the building has plenty of open floor area and high ceilings – ideal for some of the big gear either already installed or on order.

Already one five axis machining centre is installed - which will handle a component of 6metres x 3 metres by 1.5 metres. Kerry Jones, who is in charge of the machining at Core Composites describes it as 'the Baby'. But it is the biggest machine of its type in New Zealand.

One of the ovens in the very ample BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo

A second 'Monster'machining centre will take components up to 26 metres in length.

'We have these two five axis CNC machining centers, a CNC lathe and some other equipment basically to handle the capacity that we have rather than outsourcing all the parts that we do for the rigging', explains Jones.

'We probably will outsource some specialised components – when it comes to America’s Cup boats we will have to do the hulls in America. That is in the Protocol', explains Chief Operating Officer, Stephen Barclay.

The grand scheme is to be able to build all components for the AC45 class on site and thanks to some liberal rules in the new Protocol for the 34th America’s Cup, only the hulls of the BMW Oracle Racing’s AC72 yachts need be constructed in the USA. A special team will be sent from New Zealand to USA to do this.

The AC72 wingsail, foils and all other components can be manufactured in the Warkworth facility.

The five head 'baby' machining centre in the BMW Oracle Racing building facility - Warkworth. Capable of taking material up to 6 metres in length (the largest machine of its type in NZ) a second machine capable of handling 26 metres is on its way. -  © Richard Gladwell?nid=74716   Click Here to view large photo

'We have the capability to do everything,' adds Jones, turning to the big five axis machining centre, which he refers to as 'the Baby'.

'This is the smaller one of the two that we have', explains Jones. 'It has a tilting rotary head so we have full five axis of movement on the head and a 6-meter stroke by 3-meter by 1.5 meter on the Z axis. '

Think of three dimensional drawings with width depth and height ('X', 'Y' and 'Z' dimensions) and you have an idea of the composite engineering art forms these machines can produce.

'It is the only one of its kind in New Zealand at the moment,' says Jones. 'We are getting a bigger one which is going in what we call the boat shed (really a huge two or three level room the size of a warehouse).

'This one will fit on the table of the big one', explains Jones to underline the size of the new beast.

The 'room' where the big machine centre will be based - BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo

'It is designed for the aerospace industry, and making spar component parts, it is quite widely used by Boeing and companies like that. It can machine up turbine blades, and not just marine stuff, but also automotive and aerospace components,' he adds.

'The machine are going to be used for doing a lot of the mould work for the composite construction', explains Barclay. 'We get the designs from the design crew and then we convert that into cutting files and then we basically supply all the mould components to the boat builders.

'In the past we would have to an outside company to get tooling and components made. That cost a fortune and you are beholden to the outside companies in terms of timing and things like that.

A larger oven at the BMW Oracle Racing building facility - Warkworth. Even so, this is one of the smaller ones planned. -  © Richard Gladwell?nid=74716   Click Here to view large photo

'By having these machines in-house we can do all of that stuff ourselves. Of course over time we can amortise the cost of it, so if we have a long-term use it will actually be cheaper for us to be able to handle this capability in-house. '

As mentioned 'the Baby' can handle components measuring 6-meter by 3-meter by 1.5 meter.

And the big one?

'The big machine is going to be 26-meter long by 6-meter by 3.5 metres' says Jones, drooling ever so slightly.

Barclay explains that 'the Beast' is going to be hitting a roof in the boat shed. 'It will be 9-meter high. It is a massive machine that can basically machine a whole boat - the whole hull. It will take up most of this shed - with a sail-loft at the other end.'

Another machining room - BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo


BMW Oracle Racing purchased the facility about 18 months ago

'The ambition and reason why we did it was that the team has aspirations of being around for a long time . We spent so much money to finish products around the world so that is really the reason for doing it, it actually saves us money. And of course, we can guarantee the quality which for any big team is really important,' explains Barclay.

About 50-70 boat builders will be employed at Core Composites, the reason for the shift to New Zealand is that the labour costs are less and the skills and engineering expertise are high. 'We are looking at working with a lot of New Zealand’s resource to help us with the AC 45 project and we are actively talking to a number of contracting companies at the moment', says Barclay.

Another plus for the Warkworth facility is that it allows the storage of an enormous amount of kit. 'When you have been an America’s Cup Team in operation since 1990, you acquire a lot of gear', explains Barclay resignedly. 'It will be good to see what we really have in the one place.'

AC45 male mould under construction - BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo

Construction is well advanced with the male moulds for the AC 45 class of which six are expected to be sailing by mid-2011. The first will be launched in January 2011. Each competing team in the 34th America's Cup will own at least one of the yachts, maybe two. The wingsails for the AC45's will also be built in Warkworth on the same floor.

Right now the focus of Core Composites is to get the AC45’s into production.

'It will be America’s Cup Race Management and the yet to be appointed Regatta Director’s responsibility to determine who gets their boats first, and overseeing the training program we are looking to put in place before Christmas,' says Barclay.

AC45 male mould under construction - BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo

'The idea is that all the teams can come down and learn about these, and learn about sailing the boats and learn about the logistics of the wing – all that sort of stuff.

'It is the Regatta director’s job to make sure that all the teams are handled in a way that is fair and equitable.'

'We are certainly up and running.'

Male moulds and oven - BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo




by Richard Gladwell

  

Click on the FB Like link to post this story to your FB wall

http://www.sail-world.com/index.cfm?nid=74716

2:18 AM Thu 16 Sep 2010 GMT






Click here for printer friendly version
Click here to send us feedback or comments about this story.

Click for further information on
2013 America's Cup

Related News Stories:

27 May 2014  America's Cup: Oracle Team USA under stress
23 May 2014  America's Cup: Oracle and Team NZ designers reveal AC72 secrets
22 May 2014  America's Cup: Artemis death verdict 'result of an human act'
10 May 2014  A year after the Artemis incident, the sailors tell of the pain
01 May 2014  America's Cup: Oracle and Team NZ tech insights - Free lecture tonight
16 Apr 2014  America's Cup: Expected de Ridder penalty should be reduced
14 Apr 2014  America's Cup: Dean Barker's Blog - A sail with the Duke and Duchess
12 Apr 2014  America's Cup: Coutts claims ISAF Jury on a crusade, backs Kiwi report
10 Apr 2014  America's Cup: Two Kiwis escape hometown action in AC45 rules ruckus
03 Apr 2014  34th America's Cup: A Match of three weeks - Part 3 - Under the Pump
MORE STORIES ...

News - USA and the World















The first annual WetaFresh is a big success by Tim Wieringa, Muskegon, MI


















Techno 293 Worlds - France and Italy claim titles by International Windsurfing Association,














420 World Championship - Singapore and Spain out front by 420 International Class Association,




















2014 ISAF Sailing World Cup final qualification system published
Chicago Yacht Club Race to Mackinac - Karma Sailing Group wins
Red Bull 49erFX: Easing into the Olympic scene at Rio
Kempe thrilled to invite himself to Gold Cup party
2014 420 World Championships - Singapore wins Day 2 race
Lightning strikes cut short CFJ Nationals
Etchells Invitational Cup - Girls on top in Cowes
National Sailing Hall of Fame reveals inductees
J/111 North American Championship - Wind Czar victorious
Sevenstar Round Britain and Ireland Race sets off August 10th
PWA Fuerteventura Grand Slam - Antoine Albeau victorious on day 5
Snipe Western Hemisphere and Orient Championship headed for San Diego
WPA Championships - Kids race divisions offered
New Clever Pig launched by US Sailing
America's Cup: Group agrees to co-operate in London Meeting
Copa del Rey Mapfre - Build-up reveals some remarkable enthusiasm
Marblehead NOOD Regatta - Images by Leighton O'Connor
America's Cup: Two AC72 skippers discuss Foiling Moths and the Cup
RS Feva World Championship - Brilliant sailing on day 2
America's Cup: Alameda makes overtures on Venue hosting for San Fran *Feature
Cape Panwa Hotel Phuket Race Week 2014 - Relishing a challenge   
Edgartown Race Weekend - BBBR and Round-the-Island Race winners named   
Etchells Invitational Cup - Aussies take early lead in Cowes   
PWA Fuerteventura Grand Slam - Antoine Albeau strikes back on day 4   
Aquece Rio – International Sailing Regatta - All set for test event   
ISAF World Sailing Rankings for 28 July 2014   
29er World Championship - All set in Kingston   
ORC World Championship - Third Course area opens for huge fleet   
Day one of the Allen RS Feva World Championships   
Anna Tunnicliffe: Final two days of the 2014 Reebok CrossFit Games   
Joachim Aschenbrenner takes gold at ISAF Youth Match Race Worlds 2014   
Maxi Soh scores double wins in CMRC Summer Doubleheader   
29er World Championship opening ceremonies in Confederation Park   
PWA Fuerteventura Grand Slam - Action resumes on day 3   
Vic-Maui Yacht Race - Polishing the silverware   
Land Rover Sydney Gold Coast Yacht Race Start 2014 VIDEO   
Laser Radial Men’s World Championship 2014- Final day   
2014 Pacific Cup - Scarlet Runner wins   
Gladwell's Line: America's Cup - Joint Statement is a curious note *Feature   
ISAF Youth Match Racing World Champ - Top four battle it out for final   


For this week's complete news stories select    Last 7 Days
   Search All News
For last month's complete news stories select    Last 30 Days
   Archive News







Sail-World.com  


















Switch Default Region to:

Social Media

Asia

Australia

Canada

Europe

New Zealand

United Kingdom


http://www.sail-world.com/event_images/image/Twitter_logo_small.png http://www.sail-world.com/event_images/image/FaceBook-icon.png  http://www.sail-world.com/event_images/image/RSS-Icon.png

United States

Cruising Northern

Cruising Southern

MarineBusiness World

PowerBoat World

FishingBoating World

 

Contact

Commercial

News

Search

Contact Us

Advertisers Information

Submit news/events

Search Stories/Text

Feedback

Advertisers Directory

Newsletter Archive

Photo Gallery

 

Banner Advertising Details

Newsletter Subscribe

Video Gallery

Policies

 

 

 

Privacy Policy

 

 


Cookie Policy

 

 



This site and its contents are © Copyright TetraMedia and/or the original author, photographer etc. All Rights Reserved.  Photographs are copyright by law.  If you wish to use or buy a photograph contact the photographer directly.
XLXL WAS US
LocalAds   DE  ES  FR  IT