Prototype Workshop

Where design becomes reality

A CAD model, no matter how detailed, cannot reveal how a boat will actually handle until it meets the water. That is why our Prototype Workshop is designed to translate engineering data into a physical, seagoing craft as quickly and accurately as possible. Every new Aquafarer model —?and every significant custom build —?passes through this workshop before the production tooling is committed.

The workshop is fully equipped for simultaneous fabrication of hull, tubes, and rigging. This parallel-workflow approach cuts prototype lead time to 8-12 weeks from engineering release, compared to the industry norm of 16-20 weeks. When your application demands a specialised solution, we can move from concept to on-water validation in under three months.

Workshop capabilities

The prototype journey —?step by step

1. Engineering handover —?The design package (3D model, FEA report, bill of materials, layup schedule) is formally reviewed by the workshop lead and the project engineer. Any manufacturing concerns are flagged and resolved before cutting begins.
2. Hull production —?The hull is built according to the engineering specification. For HDPE: the rotational moulding programme is loaded from the Moldex3D simulation. For aluminium: the CNC-cut plates are welded in the TIG bay following the approved weld map. For fibreglass: the ply book is followed layer by layer.
3. Tube fabrication —?Fabric is cut using CNC-pattern templates, then RF-welded into full-size chambers. Each chamber is inflated to test pressure and left for 24 h for initial stabilisation.
4. Assembly & rigging —?Hull and tubes are mated. The engine is hung, steering and controls are connected, fuel system is installed, and all electrical circuits are wired and verified.
5. Static tests —?Before the boat touches water, it undergoes: buoyancy check (full load + 30 % reserve), fuel system pressure test, steering system full-lock cycle test, electrical earth-bond continuity test.
6. Sea trial programme —?20 hours of in-water testing, detailed below.
7. Prototype review —?A formal sign-off meeting is held with engineering, production, and quality teams. Any required design changes are documented and incorporated into the production release.

Custom prototyping for unique applications

The Prototype Workshop is where we solve the problems that standard production boats cannot address. Recent examples include:

• A 7.8 m RIB for a search-and-rescue organisation, requiring a custom cabin structure with roll-over protection, integrated stretcher mounts, and a bow-mounted sonar pod —?all prototyped, fitted, and tested at our facility.
• A 5.2 m inflatable for a hydrographic survey contractor, with a cut-down transom, removable instrument mast, and through-hull transducer pockets designed to minimise flow disturbance.
• An electric-drive 4.5 m tender for a superyacht, where the prototype was used to validate range, charging infrastructure, and noise levels before the client committed to a fleet of four.

Our prototyping team

The workshop is staffed by eight multi-skilled marine technicians, each cross-trained in at least two of the three core disciplines (hull, tube, rigging). The team lead is a master boatbuilder with 16 years of experience spanning custom one-off builds to production series. Every prototype is assigned a dedicated project engineer who serves as the single point of contact for the client throughout the build and trial process.

Client involvement

We actively encourage our clients to attend key milestones during the prototype build —?particularly the initial fit-out review and the sea trial. Your operational feedback during these stages is invaluable in fine-tuning the boat before it enters production. We do not build in a vacuum; we build in partnership with you.

The 20-hour sea trial is also an opportunity for your team to familiarise themselves with the boat's handling, systems layout, and maintenance requirements, ensuring a smooth transition to service when the production boats are delivered.