I originally began by exploring the idea of building a plywood boat that could incorporate a stitch and glue method, though this quickly developed into something else after visiting a fab lab. There, I discovered the possibilities of new technology. I wanted utilise this, while preserving the essence of traditional boatbuilding.  After a visit to MAKE, a fab lab in Aberdeen, I realised that it could be achievable to build a boat in the digital workshop, using laser cutters and other facilities that are available there.

 My research into the different types of boats that are available to make involved books, online sources, and speaking to people on forums. Looking through different types of CAD designs used for the traditional stitch and glue method, I realised it might be possible to modify one of them to complement digital fabrication. Receiving advice from several people online, I stumbled upon Hannu Vartiala, a Finnish boat builder and designer. He could assist me with regards to the many questions I had, and I settled upon his “Dory” design.

Once I had the basis of the design from Hannu’s plans, I was able to optimise them so that the sheets of plywood could fit together more easily, through the addition of a teething pattern. Because the laser cutter bed measures 1100x900mm, each side of the boat had to be split into three or more pieces of wood. This was concerning, as the sides may snap from the pressure of bending the sheets around the base of the boat. However, a kerfing pattern was incorporated on each sheet, so that the wood would curve more naturally, and not snap whilst bending. Because multiple sheets were to be joined together to create the parts, it was necessary to design a pattern that would give a large surface area for the pieces to glue together, thus creating a stronger join.

Before cutting into the plywood, the design was tested using small-scale models made of thick card. The tooth thickness was altered, based on the thickness of the material that we were using. Once the small cardboard boat was built and the teething problems (pun intended) were solved, we could adjust small elements of the design. Areas that didn’t fit together as well as they should have were redesigned and tested over and over, until the fit was perfect.

Whilst modifying the design, holes were introduced into the seams of the boat. Copper ties were used to hold everything in place, as the epoxy cures. Holes take seconds to drill using the laser cutter. They are always in the correct place, at the correct size and at uniform angles.

I ordered 12 sheets of 1100x900mm of 6mm laser grade plywood to fully utilise the laser cutter at MAKE, and to ensure as much of the surface area of each piece was used as possible. Laser grade plywood is weaker than that of traditional or marine grade ply. Due to the low porosity and the wood glue used to sandwich the layered sheets together. Using laser grade plywood was a worry at first. It was quite daunting, especially as I was going to be using the wood to build a boat. Usually, 12mm marine grade plywood is the standard choice for boatbuilding. The laser cutter, however, cannot cut anything thicker than 6mm, so it would have to do!

Once the wood arrived, we could start to manufacture the boat. This involved a lot of cutting, but it didn’t take too long. Mistakes were made, but fortunately there was a surplus supply of sheets. To glue the sides together, the wood was laid flat onto a set of tables, glued, and tied together until hardened. We made small tools to assist with keeping the wooden sheets flat, and together.

Entropy Resins supplied me with enough “Super Sap One” epoxy for the entire project, through sponsorship. I contacted Entropy Resins because of their use of environmentally friendly manufacturing techniques, which have a low carbon footprint on the planet. The chemicals used in the production of the epoxy, for example, are based on renewable, plant-based carbon.

After the sides and base of the boat’s panels were glued together, we could piece the sides to the base. The teeth enabled the sheets to join together and lock in to place with ease. These were again, held with clamps, and tied with copper wire. We coated the joints with epoxy to ensure there were no gaps.

Once the outer hull of the boat was built, the supports for the inside could be laser cut, along with the seats. They were then glued in place. The inner supports widened the boat, creating a much stronger hull. The seat base was slotted over the supports, which served as a guide to where to position the seat, and as a tool to lock them together.

The boat was given one full coat of epoxy, which strengthened it instantly. The small holes that were initially drilled for the copper wire to go through - to tie the boat together while using the epoxy - needed to be filled. Instead of filling them with epoxy, I decided to infill them with copper dowels that I made from copper rod. This was a really time consuming process, but I feel that it added a lot of character to the boat, echoing traditional craftsmanship methods.

Continuing on with remaining true to traditional techniques, I decided to create sheathing. This came about by beating a copper plate, so that it was shaped over the transom of the boat and the base. Copper sheathings were used traditionally on much larger ships, in order to protect the boat against barnacles, and in some instances, increase the speed.

Once the main structure of the boat was complete, the next step was to cut and lace the Halley Stevenson waxed canvas to it. The seat was designed with laser-drilled holes in order to tie the material to the seat. Additional holes at the other side were made to fashion a storage area at the front of the boat, also using the waxed canvas.

It made sense to use Halley Stevenson’s waxed canvas, as the company is not only based nearby in Dundee, but also renowned for having produced the sails on the Antarctic expedition ship, Discovery. I wanted to try and link this boat back to traditional methods and local resources - hopefully to kick-start local manufacturing again in these historically industrial towns.

In the future, due to a potentially higher rate of flooding from rising sea levels, it may be a necessity to build boats quickly and efficiently, using digital methods. This project was a brainstorm session in amongst many other ideas and other methods that could be used to answer the above problem. Especially when we reached the river and noticed how high the water was on the banks. The process of building the boat harboured many other new ideas, and how this method of manufacture and ideas could be applied.

I set sail and it was such a great feeling, I yearn to do more projects like this and to bring people along with me so they can have fun too.

The biggest problem was transporting the boat. I’ve designed other boats in retrospect and came up with a few solutions. A concertina design, for example. I’d hope to utilise the laser cutter again, but using far less sheets. I’d like to incorporate and new techniques, or improve existing methods such as fully waterproofing cotton.

For the next boat, I would like to make a flat pack that can be assembled in situ. Using modern materials might reduce weight, but I’d like to find a way to retain an element of artisanal qualities through doing so. Until then I’ll be researching further into the naval architecture of boats. So I can design my own boat completely and learn more about the initial design of the hull. Until then I will continue to be reading books and internet sources.

There were so many ideas developed whilst completing this project. The plan is to release the files so that people all around the world are able to laser cut boats and assemble them quickly, the way I was able to in the centre of town.

-Sean Fisher

The film below was directed and filmed by myself and also filmed and edited by Abby Quick.

The Film below was made for use in social media particularly Instagram where you only have one minute to convey a story through the use of video. The video was filmed and edited by myself and additional filming was done by Abby Quick.

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