Our panels will arrive at your factory preformed and precut,with a step-by-step “foolproof” instruction guide on how to place them in the mold and that’s it! You’re ready to lay up and infuse.
Our expertise and proven technology are at your disposal,including on-site support if requested. We work with you to build lighter, stronger boats faster. You will save up to 80% in installation time, 30% in resin uptake.
We have delivered splineCore kits made of PET, PMI, PVC and SAN foams (Corecell®). If you are using a different type of foam, we can perform standard thermoforming tests and develop the adequate process for your kit.
At bespline, we thermoform composite core panels with a proprietary technology we call “Adaptive Molding”.
It is a single tool that can be digitally controlled to take different shapes.
This system comprises a membrane on top of actuators that create the precision shape in minutes.
From our customer’s 3D drawings/CAD files, we split the final structure into panels optimized to minimize waste. We generate drawings with features marked such as chamfers, cut-outs and inserts. Panel shape and thickness are analyzed, and spring-back correction is applied. Our software then converts the finalized panel drawings into the control program for our adaptive mold.
These are rigid 3D shaped foam kits tailored precisely to your project and delivered to your door. They can be made of any foam core material such as PET, PVC, PMI, SAN (Corecell®), and more.
Embodying the latest processing innovations in composite core materials, these kits eliminate double-cut foam with slits that fill with resin, weakening your boat structure. This approach removes that wasted resin which also translates into cost and weight savings.
Depending on the material and the thickness, our adaptive molds can reach a radius as small as 250mm (10”). Our engineering team can assess feasibility directly from your CAD file during the splineCore kit mapping process.
Once we receive the plain foam core, our standard lead time is 2 to 4 weeks before shipment.
Yes, we provide a comprehensive step-by-step guide on how to install the splineCore kits, and our team is available to help you at any time. We are happy to provide on-site support upon request.
| Feature | Kerfed 2D Core Kit | splineCore Kit |
|---|---|---|
| Structure | Resin-filled kerfs introduce numerous small discontinuities along shear paths. | Stiffer panels provide uninterrupted shear load transfer. |
| Resin | Consumes extra resin to fill gaps and open kerfs. |
|
| Weight | Resin accumulation increases weight unpredictably, adding hundreds of lbs to hulls. | Predictable laminate weights enable more precise design calculations and accurate results. |
| Durability | Kerf zones concentrate stresses and may accelerate fatigue. | Ensures more uniform load distribution and strengthens the hull for improved performance. |
| Cosmetics | Topside core grid may print through due to differing shrinkage rates, necessitating repainting. | Monolithic core eliminates grid pattern print through, ensuring superior long-term aesthetics. |
| Efficiency | Extra labor needed for orientation; kerfs introduce uncertainty in resin flow during infusion. | Rigid 3D core components fit securely in the mold, ensuring precise alignment without shifting. |
Considering the time and resin savings, it is more economical to go with a splineCore kit than using double-cut foam panels. Starting with your first boat, you will make a lighter, more durable hull, using less resin and saving weeks of labor. You’ll further increase your savings from the second boat onwards in the case of repeat hull builds.
Yes! Starting from your CAD, we will map the shapes
into panels, even calculating the spring back from the
thermoforming cooldown cycle to make it fit perfectly
with millimeter precision. This part of the process is
called splineCore kit mapping
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