How sailing yachts are made: modern sailboat building

Stepping into the showroom of your local dealer feels as though you're walking into a modern sanctuary. Looking at all these brand new, flawlessly crafted vessels at a boat show sparks the dream of owning one of these one day. While you are underway on your journey of becoming a boat owner yourself, the question of building quality, the materials and meticulous craftsmanship will certainly pop up. So: how is your sailing yacht being built anyway? In this article we will delve into the exciting journey of how a boat is made. We will look at the path it took from mere conceptual sketches to becoming the splendid vessel you admire so much.

The (relatively young history) of modern sailing boats

Humans utilize floating objects literally since day one. The first rudimentary rafts evolved around the earliest days of coastal tribes. Soon, boats and ships underwent a rapid development: more and more structured designs, such as the reed boats of Ancient Egypt and the wooden galleys of the Phoenicians, emerged. With the advent of the Middle Ages, square-rigged caravels took to the seas, opening up new trade routes and reshaping the world as we knew it. 

Sailing as a means of leisure is a relatively young invention. Up until the early 20th Century there were just two reasons to build ships: for commerce or for war.

It was the aristocracy and rich merchants who invented the sailboat regatta, at that time a sport for the wealthiest people and kings or queens. The first recorded circumnavigator who sailed around the world for pure pleasure was the American Joshua Slocum. That was in 1895.

The boating industry, making sailboats and yachts available for ordinary people, started in the late 60ies of the past Century. Small dinghies and jollyboats made of wood, Michel Dufour´s introduction of glassfibre-reinforced hulls marked the beginning of the modern series production of affordable sailboats and powerboats for the masses.

Industrialized series production – but still 100% handmade

In the present era, advancements in materials technology have given birth to a multitude of various materials and forms of production for modern sailing yachts. New resins and fibres make modern-day boats made with vinylester or epoxy far superior compared to the Polyester-boats made 30 years ago. With the abundance and vast experiences gathered with carbon fibre composites, lightweight and stiff racing yachts made from this material are more and more becoming increasingly affordable. Vessels become lighter, stiffer and more powerful. Meanwhile, computer-aided design (CAD) and augmented reality have revolutionised the design process of yachts. Multi-axis CNC machines allow for unprecedented precision in boat construction.

Nevertheless, at the core of these leaps still lies the age-old ethos of craftsmanship and precision. Professions like master boatbuilder, carpenter and boat-joiner are still needed. Even more: The process of building a modern-day sailboat is mainly a handcraft affair. It takes several dozen highly skilled pairs of hands to shape what will become your dream boat.

It is an interesting notion that, no matter which one you go for, all of these boats are still predominantly handmade. Even the most modern and state-of-the-art equipped companies still employ a skilled workforce of boatbuilders, composite specialists, joiners and electricians who will build your yacht. A boat, unlike a car, cannot be made by a robot: it is far too complicated indeed. So remember when you are strolling over a boat show or looking at a showroom: your sailing yacht has been made by many different people.

If you are in the process of buying a new boat right now, ask your dealer for a visit to the shipyard where your boat is build. This will not only be a unique and unforgettable trip for you and the whole family, it will help to foster your buying decision and make for intimate insight into the building quality of that particular brand.

From small manufactories to mass-produced sailboats

Today, a sheer inextricable number of boatbuilders exist in the world. These companies encompass the whole spectrum of businesses: from small, family-owned and -run manufactories, mostly located at inshore lakes and in small coastal towns, to a handful of industrialized series production companies.

Whilst the latter can have an annual output of several hundred units, a small family brand may bring just a few precious boats to the water each year. These companies and different brands offer the complete range of sailing yachts in any size, any material, for every purpose and any budget. You may order a wooden marvel shaped to the wonderful classic lines of the golden past of sailing, opt for the perfect vacational cruising yacht from a series production company or have a one-off racing boat made to fit your individual needs.

The smaller a company is, the more sophisticated or specialized the boats become. As a customer, you can have heavy influence over the design, materials and specification of your yacht. Some brands are specialized in highly individualised yachts. Accordingly, waiting time for a production slot, building time and also the price of such boats are very high.

Likewise, series production boat companies put out yachts which are made to fit an average sailor´s taste: this is valid for both the sailing capabilities, the amenities and comforts as well as for the budget needed to acquire them. Waiting times for slots or to the day of their handover to you are much shorter. Also, prices needed to acquire a series production boat are much lower. In turn, the level of customization and individualisation is limited to a few options.

Modern innovations & maintaining tradition in sailboat making 

The marriage of tradition with modernity has driven a significant evolution in how boats are made. Carbon fibre and Kevlar composites stepped onto the stage in the late 20th century, almost completely ousting wood and timber as boatbuilding materials. With their superb strength-to-weight ratio, these have brought a level of rigidity to hulls unseen in older designs, curbing deformation and creating vessels that cut through the water with remarkable efficiency. On the other hand, those high-tech fibres are also susceptible to hazards, a wooden boat wouldn´t have a problem with.

Technological advancements in computer-aided design (CAD), 3D modelling or augmented reality have enabled unprecedented precision and customisation in design, optimising hull shapes, keel designs, and rigging arrangements for maximum performance. Simultaneously, using Computer Numerical Control (CNC) machines has allowed precise cutting of materials, ensuring exact adherence to design specifications. 

More and more artificial intelligence (AI) is used, especially in optimising naval architecture, appendages design and hydrodynamic shapes of the hulls. These powerful programs can run millions of computations, putting out countless iterations of parts or whole boat designs.

Yet, still, the heart of how to design and to build a sailboat still beats with the rhythm of traditional craftsmanship. It´s still the human brain and the skilled hand that crafts a yacht.

The delicate careful hand-laying of fibreglass in hulls or the artful crafting of wooden interiors remind us of the human touch. Even with high-tech materials and processes, the human touch, expertise, and passion remain indispensable, blending the new with the old to create technologically advanced and traditionally appealing sailboats. 

What is the best material for a sailing yacht?

Each material used in modern boatbuilding has its own character and properties. Depending on the size or utilization of a yacht, some materials are prone to be used, some fit better for different purposes. For example, a sailing yacht dedicated to exploring the farthest northern or southern latitudes will highly likely encounter ice and growlers: thus, aluminium may be the material of choice for such a boat. Likewise, a boat solely used in warm summers for vacational coastal sailing in a charter company doesn´t need to be built with such a high-class material, here, glassfibre will do perfectly fine. A sailing yacht destined to win the fastest regattas of the world on the other hand, where budgetary restrictions are of no concern, will be built in lightweight carbon.

Function always defines the materials used, crafting a sailing yacht is indeed a delicate balance of choosing the right materials for each component. This task requires a deep understanding of material properties and careful selection.

So, what are boats made of? Let´s delve into the most common materials used in sailing boat construction, exploring their properties and the reasons for their selection: 

While each sailing boat is unique, with variations in size, shape, and purpose, specific core components remain constant. These fundamental elements play an integral role in the boat's operation and function, contributing to its sea-worthiness and efficiency. 

You can see that there is no “best material” to build a sailing yacht from. The choice is a question of where and what for the boat is used. “Classic” materials such as wood exist equally next to glassfibre, metal or carbon fibres.

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How are sailing boats built in a shipyard? 

Building a sailing boat is predominantly handcraft. The modern series production companies, however managed to optimise the process. Concepts like line assembly, modular production and fitting and other methods had been introduced to shipyards, making boatbuilding an interesting mix between industrialized processes and handcraft. These are the major steps of how a modern sailing yacht is produced:

Step 1: constructing the hull 

Since the bulk of nowadays modern sailboats are made from GRP, the hull is laminated. Therefore, several layers of glassfibre-mats are positioned into so-called moulds. Soaked with resin, the composite specialists layer by layer laminate a solid shell that will later become the boat. The outer “skin” of the hull is a thin layer of “gelcoat”, the mostly shiny white that is so attractive. There are many production methods of making a sailboat´s hull: hand lamination, vacuum infusion or vacuum injection. Some hulls are made of two parts. The outer shell is reinforced with an inlay that will provide stiffness and rigidity. For an ordinary GRP hull, it takes only a few days to make a hull.

Step 2: making the deck 

Again, most of modern sailboat decks are made of GRP or some other composite material. These are as well moulded. Almost all decks are vacuum-infused or -injected. This is a relatively young production method where the workers place glassfibre-mats “dry” into the mould. The deck is then covered with plastic. At one end the air between the plastic cover and the mould is sucked out to a near vacuum, at the other end the resin is injected. Due to the power of the vacuum, the resin will travel through the whole glassfibre mats. Pressed together very tightly, every leftover air bubble is sucked out: in the end, a very stiff but also very thin deck can be peeled out of the plastic cover once it has thoroughly dried.

Step 3: installing the engine and steering systems

Often, the dried, but still empty, hull is put on a rack. The rack is then rolled from the lamination hall to the fitting hall: Often, boats form an assembly line here or “dock” stern first onto a central working stage. For many shipyards, installing the main engine – mostly a marine Diesel, but also more and more hybrid- and even all-electric drives – is the first step of fitting the boat. It´s not just the engine: gearbox, saildrive or shaft, fuel tanks, batteries and everything needed to make a fully functional drivetrain is installed. This also includes the fitting of the rudder and steering systems, like quadrant, shaft and bearings. Then the boat “rolls” to the next assembly station.

Step 4: plumbing and sanitation 

As onboard comfort and convenience rely heavily on the plumbing systems, water tanks, and sanitation facilities, these are next to be fitted. Having already been intricately designed in the initial stages, their installation now requires the careful threading of pipes and hoses through the boat's structure - a task that calls for an understanding of the boat's layout and the systems' functionality. Often, the series production companies have mastered the system of prefabricating modules, like the bathrooms (or ship´s heads), outside of the boats in a different location. These modules are already completed and only need to be hauled into the hull, fixed precisely at their positions and glued, screwed or laminated in place. Pipes and cables need to be connected – that´s it. If done properly, installing a full bathroom onto a yacht is a matter of a few hours.

Step 5: building the interior 

The same method of inserting and fixing pre-fabricated modules is used for the cabins and the saloons of modern sailboats. These are as well completely assembled next to the boat or in dedicated boat joineries on the shipyard´s premises. One by one, either from bow to the stern or the other way round, these modules are put onboard, fixed and connected. Often the modules have already been fitted with electrical systems, lighting, electronics and other amenities. Some manufacturers still prefer the old-fashioned way of interior making: at first, the main bulkheads are put and fixed into the empty hull. The boat is now structurally sound, location of each cabin therefore defined. Then, one after another, the boat joiners and carpenters start to build the furniture. This process is far more time-consuming, elaborate and much more expensive than modular fitting and is therefore only used in smaller shipyards.

Step 6: electrical systems and electronics 

As for installing the electrical systems, the position and careful routing of cables through conduits and connection of circuits for the complete yacht has already been meticulously and detailed planned during design process. As mentioned, the prefabricated modules are mostly already outfitted with all wires and equipment when hauled into the boat. This includes lighting, heating, ventilators, and integrating communication and navigation devices, all critical elements for safety and comfort onboard. Sometimes, the modules only contain the standard fittings of the base boat, electricians are then only installing the upgrades or custom choices made by the buyers when ordering their yacht.

Step 7: the marriage of deck and hull

If you plan to visit your new yacht in the shipyard to see its construction, this is the best moment to arrive: after the boat´s interior is completely installed, the workers will put the deck on top of the hull. Thus closing the boat. The deck-hull joint is often a mix of high-strength glue and mechanical means, like screws or bolts. High-grade luxury yachts may receive a laminated deck-hull joint. Arriving at the day of the “marriage” is a very emotional occasion since after this step is done, your yacht is for the most part a proper boat now.

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Step 8: fitting the keel 

Stability is next on the checklist. A modern day sailboat´s keel can be made of a variety of materials. For leisure craft cast iron is a substantially heavy material for a relatively low price. A combination with a lead bomb or weight in the end of the keel can significantly improve the righting moment. Massive all-lead keels or carbon fin keels with lead bombs are mainly used for high-luxury vessels or all-out racing yachts. No matter the material, every keel is securely attached to the underside of the hull by means of keel bolts. The process requires extreme accuracy, as the keel must be perfectly aligned with the boat's centerline to provide balance and stability on the water. It also must never detach from a boat, even after it hit an underwater object or ran aground.   

Step 9: final finishing, quality check and pool test

The final step involves a thorough test of all installations, mechanical and technical. Everything is meticulously checked, from bow to stern. The craftsmen will apply the last finishing touches like painting and varnishing. When the quality check has ensured that every element has been constructed and installed with precision, a final test is to be passed. Many shipyards maintain a large pool, other have a dedicated station that looks like an oversized carwash. Here, the yachts will see water for the first time. Checking their floating capabilities, it´s also starting to “rain” for several hours. This way the quality team can check the watertightness of the boat, the hatches and portholes. The boat is now ready for its roll-out and transport to its commissioning port.

Finally: commissioning the boat

Depending on the size of the shipyard or company, commissioning and handover is done by the shipyard itself or a dedicated dealer. For big series production brands, often the dealerships are responsible to put up the mast, install the sails, commission and ready the boat, calibrate all technical installations and finally hand it over to you, the new owner.

How are boats made? The bottom line 

This article has only scratched on the surface of this exciting topic: the art of sailmaking remains untouched for example. Every sailboat is the embodiment of attentive precision and unwavering dedication to excellence. The choice of materials - from time-tested fibreglass and wood to innovative marvels like carbon fibre and Kevlar composites - is critical. This is perfectly coupled with the artful execution of time-honoured craftsmanship techniques, all of which are enhanced by cutting-edge technology. Modern sailing yachts, be it the precious one-off or an affordable family cruiser made by a series production company, are fascinating objects, masterfully combining craftsmanship with state-of-the-art technology: making sure, you can live your dream of venturing out into the seas.

Explore our latest collection of sailing boats, each a testament to this masterful artistry – and ask your local dealer for a shipyard visit or more information on how we are building boats.

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