What is Advanced Composites? (ADCOM)

The term “Composite” is used to loosely describe the amalgamation or fusing of two or more materials or elements. One of the earliest forms of composite was wood and resin (or glue), which combined to make simple structures, furniture, etc. Fiberglass construction, another form of composite, (fiberglass and resin) developed from this and has become a mainstay in boat construction for over 35 years. Although fiberglass materials and methods have improved, the basic principles remain. “A Fiberglass boat is not Advanced Composite construction.” Advanced Composites (advanced (v) highly developed, superior, etc) are a more sophisticated, higher form of composite construction using highly developed resins, alternate fibers, fiber blends, fabric weaves, automated compacting and curing systems and high temperature molds to dramatically increased the strength and performance of the composite while reduced weight. Unlike fiberglass boat construction, which could be carried out in a garage, the production of ADCOM boats required extensive capital tooling and equipment, expensive materials, highly trained personnel and state-of-the-art testing, monitoring and control systems. This is not fiberglass boat construction. DON”T BE FOOLED!

The RAM™ Composite system (RCS)

The RAM™ composite system (RCS) is a blended collection of known advanced composite methodology, integrated with researched and tested innovations. The adjustable, repeatable system allows RAM™ to predict and duplicate lab test results in production. By reducing production variables such as material performance and worker error, our engineers can design the craft’s structural components to closer tolerances with less need for elevated safety factors. This allows for better control on Quality. (See next Section) The system uses combinations of vacuum infused hybrid fabrics of glass and Kevlar compacted and post cured as required. All personnel operating the RCS are trained directly by the company. Although skilled trade persons are employed in senior positions, trained operatives with no past boat building experience (i.e. “that’s not the way we used to do it”) are better suited to learn the intricacies of the RAM™ advanced composite construction system. 
The use of advanced composite materials as compared to Steel or Aluminum allows RAM™ to ensure a range of enhanced performance capabilities, quality control and durability factors on a cost competitive basis. Using RCS does however require molds. The Reflex™ tri-hull has been specifically designed so that molds within a given size range can be easily expanded, either longitudinally or across the beam. This flexibility provides RAM™ with a competitive pricing and lead-time advantages in respect to meeting specific purchaser requirements with fewer molds and significantly less capital investment. Other cost savings include expenses associated with mold storage and maintenance. The Reflex™ tri-hull design also facilitates the ability to build the craft in sections prior to final assembly thereby providing easy access to increased manpower and improved manufacturing throughput. By combining and seeking patent protection for an advanced molding process, RAM™ is in the unique position of being able to build craft to exacting tolerances and produce structures with higher strength/weight ratios.

Quality Control

A system will where the performance of the structural materials is controlled with little chance of human error allows RAM™ to closely monitor the quality of its product. Combined with ISO 9000, all methods and systems are checked and tested on a programmed basis to ensure the crafts integrity. The repeatability of this system is unmatched. Unlike aluminum or steel where the welding process on each craft is reliant of the skill of each welder and all seam must be inspected or x-rayed, RAM™ has no such reliance. 

Durability

Advanced composites are very tough and durable and can be designed to flex with no degradation. These materials are well suited to the continual flexing and slamming of fast running planning craft. Advanced composites can adsorb high impacts without catastrophic failure or denting. This is not the case with aluminum.

Price and design considerations

The RAM™ is competitive from both a price and design standpoint taking into account material, direct labor and key mechanical component costs.

Raw material and direct labor costs:

The following is an overview of the of the comparative cost of steel and aluminum vs. composite based on a generic “V” hulled craft.

** All amounts in USD

The gap between aluminum and composites in respect to raw material costs is in favor of aluminum, however that advantage is more than offset by the cost of direct labor once volume production is reached.  
Aluminum is known to develop stress cracks in craft required to perform at higher speeds. This continuing expense is not generally considered in the requisition of vessels.  
Equally important is the issue of quality control at the manufacturing level. In this regard, the process used by RAM™ allows for the adherence to rigid quality standards without the need to X ray welds as required during the manufacture of craft using either steel or aluminum.

Stress Cracking

As requirements from Government and Military agencies has moved from big and heavy, to smaller, lighter and fast craft, (with littoral draft) aluminum craft manufacturers have reduced the scantlings of there craft in an effort to reduce weight and thus increase performance. Unfortunately the resulting much thinner hull plating and the constant flexing of higher performance craft has, in some very public cases, resulted in severe stress cracking. Continual repair and reinforcement has only limited the problem and builders are looking for other ways to curb the trend.

Repairs to Composites

“Aluminum boats are relatively simple to repair and can be carried out by just about any shop with a welder.’ This is a commonly quoted statement by boat building community. Unfortunately, it’s not completely true. Not every welder can successfully weld aluminum. It requires more skill and more training than welding steel. That said, there are a large number of shops that could adequately repair an aluminum boat. This is fortunate, since the newer, lighter craft being produced seem to need more stress crack associated repairs.  
”Composite craft repair requires more technical ability to perform a quality repair”. Another commonly quoted statement. This again is unfounded; in fact there are hundreds of small fiberglass shops that can easily repair a composite or fiberglass craft. RAM™ is also setting up a 24-hour toll-free hot line to deal with these types of customer concerns and advanced composite repair courses will be offered to owners, crewmembers and/or operators of Reflex™ craft.

Production Repeatability

On a one-off basis, aluminum or steel construction is very cost effective. It allows the builder to produce a craft with very little capital cost. Advanced Composite construction systems rely heavily on tooling. This makes it difficult to compete with aluminum unless molds are in existence. However, once some form of small production line has been established labor cost reductions are realized and controlled, quality, repeatable craft can be produced.

Finish

Craft produced from good quality molds have a fairness and finish vastly superior to steel or aluminum. It does not require fairing, sanding, filling or painting and yet can be produced in any color directly from the mold. At any time in the future should painting be desired, simple sanding and priming will allow for the application of several forms of paint.

Stealth. Radar signature, mines.

Unlike steel or aluminum, composites have an inherently low radar signature. This is a large initial advantage if the requirement calls for stealth. With no metallic materials in the hull, a composite craft has a great advantage where mines sweeping duties are required. Most new minesweeper craft produced today are fiberglass or composites. As requirements change and the need for stealthy craft increases, composites it is hoped will play a larger part.

Corrosion

Improved blends of aluminum over the years have reduced the degradation of the material through corrosion however, it is still susceptible to corrode over time and regular maintenance or painting may be required. Advanced composite require very little maintenance and will not corrode.

Design Curvature

Unlike aluminum or steel, composites are easy to form 3 dimensionally. Surface finishes are generally very fair and smooth and tends to remain that way throughout the life of the craft, unlike aluminum or steel. This fair and true form vastly enhances a craft ability to pass through or plane on the water compared to uneven metal surfaces.

Weight. Fuel efficiency, draft (littoral)

There have been many studies carried out comparing the weight of fiberglass (composites) over aluminum. Many relate to the old form of hand-laid fiberglass construction, which was generally quite heavy in the beginning. The use of post cured, resin infusion composites featuring fibers such as Kevlar and Carbon has changed all that. These improvements have also help craft stiffness and durability. It is now possible to produce cost effective composite craft 20 % lighter than a comparable aluminum craft. This weight reduction can result in shallower draft and increased fuel efficiency. (Or can be fitted with smaller engines for the same speed.) 

Noise Control

Most composite structures have inherent sound dampening and insulating characteristics. This can vastly reduce general overall noise level throughout a craft relating to engine and machinery noises and hull slamming or other wave action when compared to a similar aluminum craft. 

Heat and Insulation

This insulating quality also has a bearing on the overall temperature inside and on the deck of the craft. Temperatures inside a naturally insulating composite craft are generally more stable in high heat and severe cold situations than an aluminum or steel craft. (Without extensive use of insulation) Temperatures on the deck of an aluminum or steel craft in high heat can burn personnel whereas a composite deck will be cooler. In severe cold and ice conditions, ice will form and stick to steel or aluminum and in the case of deck or superstructure; unless this is removed the stability of the craft may be compromised. Generally, in severe cold conditions, ice does not easy form on composite surfaces and if it does form, tends to slide off the high gloss finishes quite easily.

Ballistics

It should also be noted that for security and defense applications, ballistic Kevlar™ can be molded into the existing structure to provide small arms ballistics protection. Further protection enhancements can easily be added via panels attached to the inner composite structure.

Fire Control

The fire hazards problems of aluminum craft and ships are well documented. Similar concerns regarding fire on fiberglass boats relate directly to the large quantities of low quality polyester based resins. Although the glass fibers hold up well, the resins, once ignited, can burn fiercely. Advanced composites use top quality resins in quantities that are vastly reduced by vacuum compaction. All resins contain fire retardant additives to further reduce their ability to support flame. Kevlar™ fiber blends are used extensively in all our craft construction. Dupont’s Kevlar™ (like Nomex™ which is used in fire suits) will not burn and can significantly reduce the composites ability to support flame.

Conclusions

There are currently no direct competitors with all of the design and technology advantages offered by RAM™ across all target markets.