KC PRODUCTION SYSTEM
Applying a single procedure in production is a shortcoming that limits the quality of the piece to the possibilities of this unique technology.
For this reason, King Composite adapts procedures depending on the requirements and not viceversa.
The system is a set of KC's own developments, proven effective, in addition to traditional methods combined to achieve the optimization of the outcome of each piece.
Since the goal is to achieve greater performance, the processes are determined with this in mind.
MOULDS
We construct male and female moulds for all our structures, to adjust for all inertias and windage requirements.
Accurate moulds
Our male moulds for masts, spinnaker poles and spreaders are made from extruded aluminum dyes to guarantee absolute precision. Boom moulds are usually female, ranging from large Park Avenue booms for the cruising yacht to high-aspect ratio, honeycomb-sandwich racing booms.
Our new five-axis CNC router allows us to build custom moulds in a very short time, providing us with great freedom of design regarding shapes and geometries.
CONSTRUCTION PROCESS
All our masts, booms, poles and fittings are manufactured from the best pre-impregnated carbon fiber available in the market.
Perfect lamination
A skilled and highly experienced building team lays up the fibers in the moulds, ensuring that they are given the correct pre-tension. Every second layer, vacuum is applied to eliminate any possibility of voids.
Precision during the lay up process is crucial to obtain the required properties of the laminate. To avoid contamination and ensure the optimum fiber flexibility, the whole lay up process takes place in a climate-controlled and dust-free cabin.
All laminates are cured in an autoclave at temperature of 120°C and pressures as high as 6 Bar. This process guarantees a mast capable of withstanding the most demanding of weather conditions.
Absolute precision
The complex shapes of some pieces – such as the gooseneck, local reinforcements, Kevlar chafe protection, or even a logo ‘engraved’ in the laminate – are achieved thanks to our numerical control cutter. This tool not only ensures an accurate geometry but dramatically reduces the production time and material waste.
Most of our fittings are custom-built in our in-house metallurgic workshop, equipped with five-axis CNC milling machines and anodizing baths.
