Italy

Cantiere Nautico Cranchi 

Yachts in Dubai for the Dubai International Boat Show 2024

SuperYacht Times takes a look at some of the yachts that can be seen in and around Dubai Marina during the Dubai International Boat Show 2024. 

A yacht spotter’s guide to Dubai during DIBS 2024

Is the custom nature of a superyacht a definitive barrier to adopting robotic automation in the build process? As Industry 4.0 reshapes manufacturing processes across the board and robot technologies evolve, the answer might not be as straightforward as you think.Something big is happening in manufacturing. It has been labelled Industry 4.0, otherwise known as the Fourth Industrial Revolution, and it’s all about bringing further automation to manufacturing processes. We know of the rise of the machines in the automotive sector (who can forget Fiat’s classic ‘Hand Built By Robots’ TV ad campaign in the late Seventies?), but since the 1980s commercial shipbuilders have also been adopting these new technologies. Programmable welding robots, for example, were a natural progression from automotive applications centred on rinse-and-repeat actions for the mass production of standardised parts.<img src="https://photo-assets.superyachttimes.com/photo/297088/image/large-94838588aeac299c922440b543cf97c0.jpeg" data-gid="gid://syiq/Photo/297088">Most large-scale leisure yacht builders today use some form of automation, whether it is multi-axis CNC machines for the preparation of moulds or components, large-scale table cutters for producing build components from sheet materials, or automated spray booths for interior fit-out and furniture components. Groupe Beneteau has started to adopt robots to apply gelcoat, while others such as <a data-gid="gid://syiq/Company/5282" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Cantiere Nautico Cranchi (Company)">Cranchi</a> use overhead Kawasaki robots for cutting and spraying fibreglass and top coat on yachts up to 24 metres.Robotic automation and assembly has become an obvious path for companies making repeatable, high-volume products, from engine manufacturers to jet-ski companies. Genmar took it a step further (before eroded sales sent them into bankruptcy in 2009) with its Virtually Engineered Composites (VEC) hulls that promised a hull in an hour and the capacity to produce 20,000 small boats a year on an automated production line.&nbsp;Surface tensionAutomating the filling, fairing and painting process for superyachts presents a series of challenges, not just because of the size and complexity of a yacht’s hull, but also with regard to the quality of finish. In the commercial sector several companies are developing automated painting robots that can crawl the hull, removing old paint and adding new, with the added advantage of handling overspray. Palfinger’s Hull Treatment Carrier is one example, and <a data-gid="gid://syiq/Company/7254" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="AkzoNobel (Company)">AkzoNobel</a> recently invested in Dutch start-up Qlayers that is building hull and topside crawler paintbots for the commercial sector (perfect for working vessels but unlikely to pass muster for superyachts).Robosurf’s solution starts with a complete 3D hull scan to calculate how much filler is needed at any given point to produce an even skin. The robot applies filler to precisely the right thickness, meaning minimum filler is used in the application process. It is also capable of fairing the filler, although that requires some clever software engineering to compensate for the vibration of the robot. It can also apply paint &nbsp;and the company produces robotic painters for the construction industry, but getting the superyacht industry to adopt that tech will likely prove more challenging. <img src="https://photo-assets.superyachttimes.com/photo/297083/image/large-423302707b5fcb7599fbd69718c48032.jpeg" data-gid="gid://syiq/Photo/297083">Late adoptersBut pundits argue that superyachts are very different. They are not consistent like small series boats or the block assembly of large ships, so the processes cannot be automated, and robot welders cannot access spaces like fuel tanks that humans can.“Shipyards are very much behind in digitisation and automation when it comes to production – they are very late adopters, which I can understand because it’s such a sensitive topic,” says Patrick MacHill, partner and co-founder of Robosurf, which has developed automation technology for surface finishing and paint application in the yachting segment. “On the other hand, there’s never been a better time because the technology is there, it’s proven and there are so many benefits.”Benefits include improved efficiency and sustainability. In filling and fairing, for example, the robotic process is more precise, uses less material and has less wastage than conventional filling and fairing by hand. Moreover, it can cover up to 10 square metres per minute, which represents a huge time saving over conventional methods.Robosurf brought its solution to market in 2019, the same year that <a data-gid="gid://syiq/Company/7254" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="AkzoNobel (Company)">AkzoNobel</a> brought out its Awlfair SF spray filler. It was perfect timing. Robosurf took an industrial robot and combined it with a steel frame on which the robot arm could move up and down to cover up to 17 metres vertically. They have since combined this with a second robot that adds mobility to the unit for horizontal freedom of movement.&nbsp;Using a 3D map of the hull, the operator can instruct the robot where to apply filler. Robosurf says the scanning of a 70-metre superyacht hull it undertook in Ancona early in 2023 took less than a day. Once the robot has been primed with the surface map information, it can cover up to 10 square metres a minute – a significant time advantage for what typically can be a very long and labour-intensive filling process.One of the limiting factors is the cost of the equipment – €1 million or more In the case of the Robosurf solution. It is a big number for a yacht builder with relatively small output, but MacHill is convinced that it can offer a very quick return on investment when the numbers are crunched and refers to the 70-metre hull by way of example.&nbsp;“The complete filling and fairing could take a year or longer, with 20 to 25 man hours per metre,” he says. “But if it costs between €800,000 and €1.5 million to complete that process, depending on where you are, that still means a RoI [Return on Investment] within a build, or maybe two.”The efficiencies in terms of material used and time saved are considerable. Further, for some yards it might make sense to rent the robots rather than buy them outright, and Robosurf plans to offer leasing from a few days up to 36 months. There are also plans to offer upgrades via what Robosurf calls app kits, which combine hardware components (the sanding tool, for example) with the software needed for the robot to use it.&nbsp;<img src="https://photo-assets.superyachttimes.com/photo/297085/image/large-e37e820ddde3bc698c11ce969c47a990.png" data-gid="gid://syiq/Photo/297085">ExoskeletonsWith medical and military applications the key drivers for development, exoskeletons are a relatively new entry to the industrial sphere. But when <a data-gid="gid://syiq/Company/2477" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Daewoo Shipbuilding & Marine Engineering CO., LTD (Company)">Daewoo Shipbuilding and Marine Engineering</a> unveiled its trials with full robotic exoskeletons in 2014, the potential was plain to see as the powered exoskeletons enabled yard workers to perform superhuman feats, such as carrying 100-kilogram pieces of metal with ease. Fast forward nine years and the technology has become commonplace with companies such as Ekso Bionics and Ottobock offering solutions for a variety of industries.&nbsp;Exoskeletons typically come in two varieties – actuated and passive. The former feature some form of power assistance, whereas passive solutions typically offer positional support or mechanical assistance to reduce fatigue when, say, working with your arms overhead for long periods. The tech has already made its way into superyacht construction. <a data-gid="gid://syiq/Company/54" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Heesen Yachts (Company)">Heesen Yachts</a> has introduced exoskeletons for some of its workforce after trialling equipment from Rotterdam-based manufacturer Skel-Ex. <a data-gid="gid://syiq/Company/122" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Royal Huisman (Company)">Royal Huisman</a> has also adopted exoskeletons for its workforce, using Ottobock’s Paexo Shoulder.&nbsp;“Our employees have to perform lengthy and difficult overhead tasks such as welding, electrical wiring and painting,” says Erik Slomp, <a data-gid="gid://syiq/Company/122" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Royal Huisman (Company)">Royal Huisman</a>’s yard manager. “They’re delighted, because using the Paexo Shoulder not only gives them the necessary support to continue performing these strenuous tasks throughout the day, but is also very comfortable to wear.”<img src="https://photo-assets.superyachttimes.com/photo/297087/image/large-4b5eca16dbefebb7cef32a44c205e6dd.jpg" data-gid="gid://syiq/Photo/297087">Collaborative robots&nbsp;Cobots – or collaborative robots – are a new type of robot that are starting to offer manufacturing opportunities. They are small, light robot arms that have been designed specifically to work alongside humans rather than separate from us. They can be programmed and controlled through smartphone apps and can be taught routines intuitively, meaning you do not have to have an army of programmers to use the tech. With multiple interchangeable tool heads they could be used for everything from sanding wood components in the cabinetry workshop to picking parts and assisting with component building. They also require much less investment than the large industrial robots, typically running to the low- to mid-tens of thousands of euros.“I think this is only the beginning,” says MacHill. “At the moment we are mainly focusing on the hull because it’s a big area that consumes a lot of time, energy and resources. But there is scope for the scanning and digitisation of the superstructure and technical areas which adds value and creates a more complete set of documentation. Then we can think about smaller robots for the smaller areas. This is something that could be developed because the technology is the same – it doesn’t matter if it’s big or small, it’s the quality of the application that counts.”There is also potential for gantry-style robot stations for the platform or series builders operating in the 30-50-metre aluminium- and steel-hulled segment, where hulls and superstructures are more consistent and where robotic solutions could speed up production processes for hull treatment prep and finishing. Moreover, installing automatic storage and retrieval systems (ASRS) could help a shipyard streamline its components and parts cataloguing, particularly pertinent given recent supply chain issues.MacHill emphasises that robots do not represent a threat to human workers, although their jobs may well change. Robots still need to be programmed, and often the people who were doing the job of the robot before are retained in supervisory and quality control capacities. Robots may also provide an answer to another problem that shipbuilding in general faces: the shortage of skilled workers in key trades.&nbsp;“We need open-minded players in all aspects and all fields to come together and work together,” MacHill concludes. “It needs a mental shift, but what they offer and the savings they deliver are amazing – who wouldn’t want this?”<img src="https://photo-assets.superyachttimes.com/photo/297086/image/large-6a937b41d9e6802a7bb424b1f5b1bf05.jpg" data-gid="gid://syiq/Photo/297086">Anti-foul playRobots have started to appear in our homes and gardens as little autonomous helpers for vacuum cleaning and lawn-mowing. Similar technologies are now being applied for ship hull cleaning in-water and antifouling applications in dry dock. They mitigate the need for humans to get involved with harmful coatings and offer the possibility to rethink how we tackle fouling. Robots, for example, were used to remove the original Chromium 6-laden paintwork using water jets from the Project Master conversion project at <a data-gid="gid://syiq/Company/429" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="ICON Yachts (Company)">Icon Yachts</a>, formerly a supply and rescue vessel.&nbsp;CleanROV, Mini-Pamper, HullWiper ROV and the wonderfully named Robotic Hull Bio-inspired Underwater Grooming tool (HullBUG) are all variations on a theme: automated hull crawlers that use vortices or magnets to cling to the hull and gently brush to remove fouling. The use case is potentially strong for yachts, which typically spend long periods at rest when fouling becomes an issue.Leading paint manufacturer <a data-gid="gid://syiq/Company/6101" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Jotun (Company)">Jotun</a> has also joined the hullbot revolution, launching <a data-gid="gid://syiq/Company/6101" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Jotun (Company)">Jotun</a> Hull Skating Solutions in 2020, and with it the HullSkater robotic cleaning device. Designed to be carried aboard and deployed regularly, <a data-gid="gid://syiq/Company/6101" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Jotun (Company)">Jotun</a> also offers HullSkater as a service rather than an outright purchase. The HullSkater was developed in collaboration with technology specialists including <a data-gid="gid://syiq/Company/6426" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Kongsberg Maritime (Company)">Kongsberg</a>, Semcon, DNV-GL, Telenor and key shipping companies, and <a data-gid="gid://syiq/Company/6101" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Jotun (Company)">Jotun</a> claims that if all ships converted to the tech it would have the potential to reduce CO2 emissions by at least 40 million tons per year.&nbsp;“Moving away from traditional, reactive methods of managing fouling to a proactive approach which will ensure that vessels are always operating efficiently and sustainably, and also conserve the ocean environment,” says Alfie Ong, global sales director at <a data-gid="gid://syiq/Company/6101" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Jotun (Company)">Jotun.</a>This article was originally published in Issue 3 of How To Build It, you can&nbsp;<a href="https://www.superyachttimes.com/magazine/how-to-build-it-issue-3" target="_blank">download the magazine for free here</a>.

The role of robots in superyacht construction

Is the custom nature of a superyacht a definitive barrier to adopting robotic automation in the build process?

Into the Future: The role of robots in superyacht construction

The Italian shipyard <a data-gid="gid://syiq/Company/5282" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Cantiere Nautico Cranchi (Company)">Cranchi Yachts</a> have released details of their flagship yacht, the 25.15-metre <a data-gid="gid://syiq/Yacht/9266" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Cranchi Settantotto 78/0125.15m (82'6&quot;)Cantiere Nautico Cranchi 2019">Cranchi Settantotto</a> that was revealed at Boot Düsseldorf earlier this year.<img src="https://photo-assets.superyachttimes.com/photo/168527/image/large-8658fc5617b4b02e6d00d93b40129a56.jpg" data-gid="gid://syiq/Photo/168527">With her exterior and interior designed by Parma-based studio <a data-gid="gid://syiq/Company/2990" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Christian Grande DesignWorks (Company)">Christian Grande</a> in collaboration with the Research Centre of the shipyard, the new model marks the entry of the 150-year-old shipyard into the 24-metre and above superyacht market.<img src="https://photo-assets.superyachttimes.com/photo/168531/image/large-714049eded22fa667be069372fe0d768.jpg" data-gid="gid://syiq/Photo/168531"><img src="https://photo-assets.superyachttimes.com/photo/168536/image/large-509850e6075dd93dc96ca1250f96c8bb.jpg" data-gid="gid://syiq/Photo/168536">The superstructure of the <a data-gid="gid://syiq/Yacht/9266" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Cranchi Settantotto 78/0125.15m (82'6&quot;)Cantiere Nautico Cranchi 2019">Cranchi Settantotto</a> yacht presents an eye-catching colour combination and a sleek profile along with a generous interior volume, letting in plenty of natural light for bright interiors.<img src="https://photo-assets.superyachttimes.com/photo/168521/image/large-30cd907891b151ea3bed14035b4b3d5f.jpg" data-gid="gid://syiq/Photo/168521"><img src="https://photo-assets.superyachttimes.com/photo/168519/image/large-1aeaecf900d49a884c2745391d740be3.jpg" data-gid="gid://syiq/Photo/168519">“For us, every project tests the skills we have gained, sometimes in very different sectors,” explains Christian Grande. The square deck design provides generous spaces and volume while also allowing an optimised layout for the interiors, namely for a spacious galley, living room and relaxation areas on the main deck alongside an open-air flybridge.<img src="https://photo-assets.superyachttimes.com/photo/168492/image/large-25be286818047f11d2df87e8f9f91b9d.jpg" data-gid="gid://syiq/Photo/168492"><img src="https://photo-assets.superyachttimes.com/photo/168494/image/large-01b3a2e93e40fdd9b3fd2a2938f9ee1a.jpg" data-gid="gid://syiq/Photo/168494">"The breadth of the space in the&nbsp;<a data-gid="gid://syiq/Yacht/9266" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Cranchi Settantotto 78/0125.15m (82'6&quot;)Cantiere Nautico Cranchi 2019">Cranchi Settantotto</a>&nbsp;pushed us towards a design with a markedly architectural matrix, which uses freestanding furniture elements and finishes that are still unconventional in the yachting world, such as back-painted glass and fabric covers for the walls. Large openings connect exteriors and interiors, integrating natural light and the sea element into the design.” he added.<img src="https://photo-assets.superyachttimes.com/photo/168490/image/large-a893f39f3d655d91267fc1c243be8561.jpg" data-gid="gid://syiq/Photo/168490"><img src="https://photo-assets.superyachttimes.com/photo/168489/image/large-f453d5a210eb2db69c8e61d3292fc520.jpg" data-gid="gid://syiq/Photo/168489">The&nbsp;<a data-gid="gid://syiq/Yacht/9266" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Cranchi Settantotto 78/0125.15m (82'6&quot;)Cantiere Nautico Cranchi 2019">Cranchi Settantotto</a> yacht features an easily-accessible swim platform equipped with a lift that allows it to be converted into a beach club while providing plenty of space for storing a tender and jet-ski.<img src="https://photo-assets.superyachttimes.com/photo/168488/image/large-18addb7483a968275d4d78bbe7deb0c6.jpg" data-gid="gid://syiq/Photo/168488"><img src="https://photo-assets.superyachttimes.com/photo/168516/image/large-3bd557566e5bdc9e2735b9104e92913d.jpg" data-gid="gid://syiq/Photo/168516">"The external decks are not designed to be a simple appendix of the interiors,”&nbsp;adds Christian Grande.&nbsp;“They acquire independence and identity by using customised furniture and accessories, as well as control over details, which we wanted to push until the advanced phases of execution, making any possible perception coherent.”<img src="https://photo-assets.superyachttimes.com/photo/114089/image/large-5bf3d4aff069992ed9b06f370204f75a.jpg" data-gid="gid://syiq/Photo/114089"><img src="https://photo-assets.superyachttimes.com/photo/114097/image/large-13f5e27ca82bddcdc94f8df7256d7ad4.jpg" data-gid="gid://syiq/Photo/114097">On board, <a data-gid="gid://syiq/Yacht/9266" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Cranchi Settantotto 78/0125.15m (82'6&quot;)Cantiere Nautico Cranchi 2019">Settantotto</a> provides accommodation for up to 18 people, and offers a layout that can include up to four en-suite staterooms with elegant furnishings. The full-beam master in the centre of the yacht with a walk-in wardrobe and a study, while a second VIP suite is located at the bow. The vessel is powered by triple 1,000 hp <a data-gid="gid://syiq/Company/5350" href="#managed-by-system" rel="noopener noreferrer" target="_blank" title="Volvo Penta (Company)">Volvo Penta</a> engines, allowing for comfortable cruising.

Looking at Cranchi’s flagship yacht Settantotto

Cranchi Yachts recently revealed the design details of their latest flagship the 25.15m yacht Cranchi Settantotto. Read more on SYT.