In early 2013 Spirit entered into the design and build of a new surf ski The 'FURY'.
Spirit wanted the 'Fury' to continue on from the success of the PRS in the roto-moulded surf ski market. With some fore thought we suggested the composite moulds which are used to make the alloy roto-moulds could be 'recycled' to create an advanced composite surf ski for the Avon Descent.
We were excited to be involved in the process and received line drawings to create a 3D model which was used to make the master pattern. Our input in the composite part to make the alloy mould ensured we could also use the composite 'part' as a mould for composite surf ski production.
Building a surf ski for the Avon descent is not trivial, over the last few years the water level has been dropping and the boats and kayaks are subjected to more rocks than usual and in some
years its even become a running event with water too low to pass through.
Considering the chances of rock impact to be high and the need for a light weight craft for carrying - we specified a 50/50 carbon fibre and Innegra hybrid cloth. The first ski was made with epoxy resin and infused to reduce the chance of pinholes (a cause for leaking) and minimise weight.
The final hull weight was 11 kg and the ski performed well, sustaining only one puncture on the keel on the first day in trying conditions Alan Albert finished top 10 on the first day and 13th across the line on the second day. The fury was also the first surf ski across the line beating multiple kayaks.
Based on the performance in this event, Spirit committed to the purchase of a 100m roll of pre impregnated carbon/innegra fabric with a modified toughened epoxy resin system. This years ski will be lighter and tougher than last years... bring it on.
Our work continued with Forlano Design with the fabrication of a private furniture commission, exhibited at the 'From the Atelier' exhibition at FORM Gallery in Perth city. 
For over 5 years we have been manufacturing foot pedals for Spirit Kayaks. In that that time we have redesigned the foot pedals 3 times. The first version was an up grade from the plastic foot pedals with carbon fibre composite foot plate, pedals and stainless steel hinges - we made over 200 of this variety.
Last year we made a prototype carbon fibre / Innegra kayak for the 2013 Avon Descent, but we needed a new foot pedal to go into this beauty - so we prototyped the new design. A foot pedal which does not even have a hinge! - the latest design uses particular laminates to allow for flex in a specific region. This idea is not new in fact the very first design (prior to the stainless steel hinges) tried a flex hinge approach but failed, with time and experience we have solved the issues which troubled us earlier and the new foot pedals are performing well. - we hope to make 400 of these ones
Due to our experience in CNC machining alloy foil prototypes for sailing boats, Andy Dovell from Dovell Naval Architects www.dovellnavalarchitects.com.au asked us to CNC machine a hydrofoil and vertical foil for a 'tow in surfboard' to be featured in the upcoming Storm Surfers film, featuring Ross Clarke-Jones and Tom Carroll, first reports are that the format is working...
In 2011, Forlano Design commissioned us to make another side table from Walnut, after the Art Gallery of Western Australia acquired the original for their permanent collection. The art piece increased in size to 500mm high (previously 450mm) and revolved around incorporation of digital manufacture, whereas the previous piece was 100% hand made from 3D and 2D drawings.
Approached by a local boat builder to make three 14' skiff hulls was like a trip back in time when I started out working as a boat builder. Using pre-preg carbon fibre over a male mould, we laid up the hulls and deck components. Vacuum bagged, oven-cured and pre-preg carbon fibre proved a good combination as the hulls come out with a good weight and excellent structural rigidity. Following on from the 14' skiffs, two Cherub hulls were also produced in the same materials and method.
Although we designed that machine to cut and mark (pen, permanent marker or pencil) primarily pre impregnated composite laminates, we have the ability to cut structural foam cores, wood veneer and intend to fit an ultrasonic cutter later this year. There are also thoughts to incorporate a plastic printer extruder head to compliment our two 'smaller' plastic printers and give us the ability to print large objects to compliment our pattern and mould manufacturing.
