Manufacturing process

 

 

  1. Engineering and calculations

    For this stage AXXON uses an experienced team of engineers who calculate, panel by panel , the forces applied to the mast taking in consideration various elements such as righting moment, chain plates location and the sail plan itself.
    This information is translated into a lamination plan which positions the various layers and local doublers as well as the fiber orientation.
  2. Mast plan

    The AXXON design office draws the mast plan along with the details drawing where the different elements of a mast are finalized : spreaders, sheaves,  goose neck, chain plates…
  3. Lamination

    It’s the stage where the various layers of pre-preg carbon are positioned into the female toolings.  Debulkings are done after each layer off axis material and the vacuum.
    Using pre-preg carbon will give you 2 advantages :

    1. Perfect control of the fiber-resin ratio which gives us a very precise weight estimate 
    2. Optimum orientation of the unidirectional fibers which guarantees maximum compression strength (impossible to obtain in the filament winding process).
  4. Autoclave

    The curing in autoclave under pressure gives us a perfect laminate with minimum void and a perfect control of the curing temperature (8h curing going up to 125°).
  5. Machining

    Machining of carbon masts requires a high level skill with special diamond toolings in order to manufacture a top quality product with no risk of delamination and respecting the finest tolerance.
  6. Finish

    AXXON applies 3 to 12 layers of varnish or paint in order to protect the resin and fibers from the UV.
  7. Assembly

    All pieces are controlled, assembled and fit on the mast. The electric and electronic cable are run into a conduit tight up inside the mast and various brackets are fixed to the mast.