How a hull
is made in fibreglass
Fibreglass is a composite material: glass fibres embedded in a resin, polyester or vinylester, which as it cures binds them into a single shell. The fibres provide the strength; the resin holds the fibres together and gives the shape. The result is a rigid hull, light for its strength and able to last over time, if it is treated as it should be.
A fibreglass hull is born inside a mould, upside down. For the NAVY RIBs the moulds are designed by Italian engineers, with hull shapes studied for seakeeping. The gelcoat, the outer skin, goes into the mould first; then, layer after layer, the fibreglass. On the NAVY RIBs lamination is done by hand or by infusion, depending on the model. In hand lay-up, each layer of fibre is wetted out with resin and rolled by hand until the air has been driven out. In infusion, the fibres are laid dry, the mould is sealed under a vacuum bag and the resin is drawn in by the vacuum itself, evenly.
A hull does not work the same way at every point. The most stressed areas, those that take the blows of the waves and carry the engine, are reinforced on the NAVY RIBs with multiaxial fabrics or reinforcing cores, for more stiffness without adding weight. This is what we mean when we write «increased thicknesses»: fibreglass placed where it is needed, added, not taken away to save money.