Our CAD Yacht Design Process

How We Use CAD to Design Boats

And to Develop CNC Cutting Files
For Pre-Cut Boat Parts
Copyright 2011 - 2015 Michael Kasten
Updated December 2015

This page contains a summary of how I use CAD during the development of a new yacht design, and then leve
building the vessel by direct use of the computer-generated model. As an extension of this article, please also s
prefer NURBS Surface Modeling to originate our boat and yacht design.
The Design of a new yacht is ordinarily divided into three basic stages:
I. The Preliminary Design Sketches
II. The Study / Estimating Plans
III. The Final Building Plans.

Those are the basic 'Design Stages' that must be completed before a new yacht design is ready for the builder.
Design Process itself please review my separate article on Custom Design. Below I will focus instead on the C
of good use, and how the CAD generated 3D model can be leveraged for actual construction of the boat.
Beyond the various essential 'design' tasks required when creating a new vessel, there are several actual 'boat
designer can become involved. For example, a natural extension of the designer's work is to detail the vessel's
order to make pre-cut boat parts.

Below, we'll have a look at how the 'design' and the 'building' processes are augmented by the various software
Marine Design, Inc. While we make extensive use of basic Microsoft Office software such as Excel for nume
specifications; and Adobe Acrobat for generating plots and final documentation, the following article will ins
specialized software tools - generally referred to as "CAD" (Computer Aided Design).

Our "CAD Design Stream" is best understood if it is separated into four discreet 'design related' boat building
designer, plus two additional tasks done by the cutting shop and the builder... per the following outline:
1. Creating the Design
2. Generating the Structure
3. Detailing the Parts
4. Nesting the Parts
5. Cutting the Parts
6. Building the Boat

These various tasks are outlined below, separated according to how each task makes use of various different C

I. Creating the Design

MODELING

We begin the design process by modeling the general shape of the hull, decks and superstructure. For the initia
found Maxsurf boat and ship design software to be intuitive, highly capable, and accurate.

At the beginning of any boat design project we will create a model within Maxsurf Modeler, using a collection
Often this is done by modifying an existing Maxsurf design to suit a new requirement. When it is warranted, w
model - usually borrowing elements from prior designs in so doing.

The Maxsurf model is refined as needed for the emerging concept design. When the model has been sufficien
the "container" for sketching in the preliminary accommodations layout. With feedback from the preliminary l
model will be revised to suit.

The Maxsurf model is refined as the design matures, so that at the end of the design process the model can be
drawing. The completed model will include the hull, bulkheads, soles, tank faces, decks, bulwarks, houses, sup
and other appendages. In other words, the model is as complete as it can be in terms of the structures that defin
internal compartments.
ANALYSIS

In addition to its excellent modeling and fairing tools, Maxsurf also has a variety of tools for assessing prelim
programmable calculation sheet which can be set up to provide nearly any hull-form related calculation (e.g. p
fuel requirements, etc.).

For further analyses we make use of various other components of the Maxsurf software family such as Maxsu
stability and trim, Maxsurf Resistance (Hullspeed) for resistance, Maxsurf VPP (SPAN) for sailing performanc
(Seakeeper) for sea keeping / motion analysis.

Our primary stability and trim analysis tool is Hydromax, wherein we are able to model the tanks and analyze
additionally has comprehensive built-in tools for assessing compliance with various international stability crite
ISO, the IMO, and the US Coast Guard.
To understand the rationale behind why we consider NURBS Surface Modeling to be a superior approach not
vessel but also for the sake of accurate analysis, please see our NURBS Surface Modeling web page.
DRAWING

Once we have finalized the design we will begin to detail the model for construction. Since we use other CAD
and detail drawings, we will export the lines as 2D or 3D DXF wireframe views for further detailing within a C

We find that CAD offers a number of efficiencies that may not be readily apparent. For example, by compariso
pencils and erasers on vellum, within a CAD based workflow we are able to quickly migrate myriad details fro

efficiency not readily accomplished with hand drafted details. Also we are able to make changes more quickly

Further, the CAD drawings can easily be shared across our local network or by email, allowing us to co-develo
design team members' locations. Of equal value is that "screen shot" images or PDF plots of the emerging desi
as a communication tool with our clients - also independently of our respective locations.

With CAD, when the design is completed, we can offer the same kind of support to the boat builders in the for
cases, directly via the CAD files themselves.

II. Generating the Structure

If the design is to be NC cut, the Maxsurf-generated 3D NURBS surface model will be opened directly within
the construction module of the Maxsurf suite of programs.

As can be seen in the images to the right, within Workshop we are able to automate the generation of the vess
structure, including placement of stringers and frames. Once the frames and stringers are defined, Workshop w
frames so that they precisely match the hull shape, and will calculate and place the various cutouts for the strin
Plates are also defined within Workshop, and the plate shapes are then 'expanded' onto flat sheets.

When completed, the entire collection of Workshop parts are exported as 2D DXF entities (the expanded plate
for further detailing and nesting within a separate CAD system.

Frames Exported from Workshop to Rhino - Click for Larger Image

III. Detailing the Parts

DETAILING

We use Microstation for CAD drafting, for NC parts detailing, and for NC plate nesting. "NC" just means "N
general term we use to refer to the process of cutting out metal boat parts from flat sheets using a computer dri
ways that the cuts are accomplished on steel are to use an oxy-fuel flame or a plasma jet. For cutting aluminum
abrasive water jet or a router.

If the design will be NC cut, the parts will first be generated within the Workshop program, then exported in D
and detailing within Microstation.

Microstation can work directly with DXF and DWG files from any version of AutoCAD. This is a trick that e
rather intentionally will not) do. Microstation is also able to import IGES files and Rhino *.3dm files if desir
further NURBS surface modeling or detailing.

As can be seen in the images to the right, within Microstation the Workshop-generated parts are being edited a
necessary, additional parts are generated. By convention, whether we are working in 2D or in 3D, within Micro
frames imported from Workshop upon the body view imported from Maxsurf in order to verify that the variou

correctly interpreted. We will also superimpose any prior interior or other relevant views by attaching CAD ref

Once detailed, the parts are labeled and grid lines are edited or added as needed. Text, marking lines, cut lines
placed on separate layers, each of which are color coded according to the requirements of the NC cutting servi
nested, large parts will be cut into smaller pieces for the sake of efficient nesting onto standard plate sizes.
PLOTTING

At this stage we create "Plot Files" of the assembled parts that illustrate their layout and assembly. For exampl
entities (prior to nesting) and the plates are arranged to show their relationship to each other and to the whole.

These "Plot Files" are turned into a series of PDF files which are then sent via email to the owner and the build
be needed. The owner, builder, and the builder's subcontractors or vendors can plot the PDF drawings to scale
copy shop plotting service.

Additionally, the actual parts assembly files are occasionally useful to the builder, in which case they will be p
directly to the builder - also by email.

IV. Nesting the Parts

At this point, the "Plot Files" of the parts assemblies are preserved as-is for future reference. Those files are th
where they are further detailed for NC Cutting. Creating the actual Cut Files consists of performing the slicing
available plate sizes, then organizing the CAD files and the entities they contain per the requirements of the cu

The files are first organized so that each file only contains parts having the same plate thickness. There will or
Frames, Plating, Tank Faces and Lids, Engine Stringers, Stem and Keelson, and for Stringers (if there is suffic
warrant developing longitudinal stringers).

Then the "stock" plate sizes available from suppliers are drawn into each file to scale, and the frames or other p
efficient nesting. For example, all parts of 3/8" thickness will be within one file so that, using standard 3/8" sh
given sheet can draw upon any 3/8" part for maximum nest density.

In order to get the most efficient use of plate, we will ordinarily do most of the nesting manually. Software is a
not 'smart' enough to make the various decisions required to achieve an efficient 'nest' of parts, for example to
that it can be most easily welded back together after cutting.

When the nestings are complete, there will be an array of stock sized plates of equal thickness within each file
of parts. Additional labeling is introduced to identify plate sizes, plate thickness, alloy specification, etc. Prior
cut lines are error checked within Microstation in order to correct any minute line crossings, unintended smal
duplicate entities.

Finally, the nested parts are output as DXF or DWG files for use by the cutters (who almost universally use Au
DXF / DWG files are the actual completed "Cut Files."

V. Cutting the Parts

Cut Files: Since it is far less expensive to send the parts definitions by email than it is to send the cut metal by
will always try to make use of metal cutting shops that are closest to where the boat will be built. We will asse
into a series of ZIP archives, and ready them to be sent by email directly to the cutter who has been chosen for

The builder will ordinarily purchase the plate and have it delivered to the cutters or in many cases the metal su
in-house. After the parts have been cut they will be shipped to the builder's yard. In this way, the builder ordina
materials, as well as the cost of cutting and shipping.

Tabbed Parts: Among the images shown to the right, one illustrates an NC cut plate that has been delivered to
for the sake of easier shipping. By this means, although all of the parts have been pre-cut, small 'tabs' have bee
the part edges. This is done so that the parts all remain in easily handled, easily shipped, and easily referenced
matter to cut the small tabs to release the parts. It also allows the builder to instantly tell if any of the NC-cut p
are common in New Zealand and Australia, but oddly this is not often done in North America.

Markings: In the tabbed cut plate image to the right, take note that the parts have been marked with an ink-je
to use the plasma or water-jet heads for etching the markings. This is brilliant, as it vastly speeds up the markin
and text are accurate and easy to read, and the ink-jet does not impose any heat or stress on the plates. Again, t
common 'down under' but, oddly, not in North America.

Quality Assurance: During the cutting process, our follow-through is an important part of our design service.
essential in order to accommodate the varying requirements of the various different NC cutters we encounter. F
built in New Zealand, we will customize the job to their specifications and adapt the nestings to metric plate si

Since we work with a variety of metal cutters, it is often our practice to first send one component through the c
often this is the rudder, since it is relatively small but consists of precise foil shapes for the lifts, and a precise o
component is satisfactory to the builder, has clean cut edges, and the parts accurately fit together, then the rest
sent through. On the other hand, if a builder has established a reliable track record with their cutter of choice, t
this precaution.

VI. Building the Boat

Why is building the vessel listed as one of our 'design stream' stages...?

Because by the time the metal arrives at the builder's yard, we will have already done quite a bit of the actual b
our computers...!

So although we do not 'build' boats per se, we are indeed very much involved in the actual boatbuilding proces
nested, sent out and NC cut, we maintain a close relationship with the builder as well in order to be sure they f
fabrication should be accomplished.

Other Materials..?

Though the above summary has focused on metal boats, NC cutting can also be used for router cutting of plyw
structures, whether they are for hull and deck structures, or for boat interiors. Even on a metal boat, the interio
other flats can be detailed accurately within the CAD model, then pre-cut and delivered to the builder.

Yet another application for the 3D modeling methods described above is for direct 3D cutting. Here, the NURB
directly by a 5-axis router to carve out the shape that has been modeled. Most commonly this would be used to
for GRP construction of a hull or superstructure. This approach saves an enormous amount of the builder's in-h
shop space.

Another application of this technology is to create a scale model, whether just for fun, or to verify the aesthetic
tank testing. For a bit more information on this please see our brief web article on Prototyping & Developmen

A somewhat unusual project is the prototype shown above and to the right... It is the Piranha, a prototype / con
in Maxsurf and rendered in Rhino. The intent was to have a mould cut by NC router so that the various body
For the Piranha, Kevlar and vinyl ester resin would yield a structure that's stiff, light, strong... and bullet proof

For the Piranha retro-rod we could elect to have the NC router carve a female mould and we would be able to
immediately. However the NC cut moulds are typically made of reinforced foam, so they are only good for up

If a larger production run were anticipated, we would instead have the NC router carve a male plug for each p
much more durable mould for each part. This would permit making many dozens of GRP body parts from the

This kind of NC Cutting technology is well established for all manner of manufacturing endeavors, and there i
Economy..!

A Design-Stream Overview

The following flow-charts were created in order to show our design process - more or less taking the usual "de
into a linear diagram. I have used two different ways to represent the work-flow, plus a link to our Maxsurf pa
the software described above..

Software in Use - This is a simplified flow chart showing the software we use, and how a few basic sof
the process of creating a new yacht design.
Process & Deliverables - This is a workflow chart showing our Design Process arranged in terms of the
follow in order to create each new yacht design. This process starts with our interaction with the client,
the design process, and finally produces the drawings and documents that we deliver to the client, the b
Maxsurf - Software for Boat and Yacht Design.

Cool 3D Models

The following are two examples of how we make good use of a 3D CAD workflow in order to create a design
communicate the result using 3D PDF files for use by both client and builder.

3D Lines Drawing - This is a 3D perspective file showing the lines of one of our designs. As with all o
Maxsurf, then imported to Microstation so that it could be "plotted" to a 3D PDF for customer review
the 3D model, rotate it, zoom, pan, walk-through, and you can change the perspective. If you turn on th
manage the layers in the original CAD drawing, turning any of them on or off to simplify the view. Thi
visualization of the spaces, and to see the vessel's shape from any angle.
3D Structure Drawing - This is a 3D perspective file showing the structure of a metal yacht design. Ha
Maxsurf, the vessel's structure was then created in Workshop; after which the basic structure was bro
editing and detailing, and then "plotted" to a 3D PDF for the builder to use as a guide during assembly.
the structure using simple, free Adobe Reader software. This enables the builder and his crew to see e
interrelates.

Design Information

While we regularly develop NC cutting files as described above, we do not sell "parts kits" per se. In other wo
materials. Instead, we offer Building Plans and NC Cutting Files for any of our pre-existing designs, or for n
services for design, analysis, and parts development.

Once we have completed a new custom design, or whenever we have provided a client with one of our pre-exi
make recommendations and introductions to qualified builders who we consider to be suited to the task at hand
will prefer to provide a bare hull, others a power-away package, and yet others will only take on the constructi

Although our Building Plans packages are very complete, we very much prefer to stay involved during the boa
might be clarifications desired on the part of the builder, or if there are possible changes introduced by the own
drawings might be requested, etc.

Where To From Here...?

For pricing and ordering information on any of our pre-existing boat designs and NC cutting files, please see o
Whether we create the NC files from scratch, or offer them as part of a stock design package, we still include o
metal cutting.

In advance of developing any new boat design or other modeling project and prior to developing NC Cut Files
Design Proposal that includes an estimate for our work that is based on the scope of the project that has been

For more information about creating NC Cut files for any of our designs, or possibly to generate NC cutting fi
contact me as needed.