Leopard Catamarans Advances Hull Construction with Single Shot Infusion

In a move aimed at increasing efficiency and structural integrity, Leopard Catamarans—the sailing and power catamaran brand built by South Africa’s Robertson and Caine (R&C)—has introduced a new hull construction process called single shot infusion. This updated technique marks a significant shift in the company’s lamination strategy, replacing the traditional multi-stage infusion method with a streamlined, one-step approach.

The single shot infusion method saturates the entire hull structure—core, laminates, and reinforcements—in one controlled resin application. By doing away with secondary bonding steps, the process improves uniformity, reduces weight, and enhances the long-term durability of the hull. According to R&C, it also minimizes the risk of delamination by eliminating inconsistencies along join lines.

The adoption of this technique comes as part of a broader focus by R&C to modernize production and increase quality control measures across its manufacturing pipeline. Complementing the new infusion method, the company has also implemented advanced acoustic leak detection systems to ensure vacuum integrity prior to resin application.

Further updates to the hull-building process include a redesigned resin feed layout to reduce dry spots, second-round phenolic sound testing 30 days after demoulding to catch delayed anomalies, and a trial of thicker print blockers to improve surface aesthetics and minimize visible patchwork over time.

Robertson and Caine, which remains the largest boatbuilding company in South Africa and a global leader in power catamaran manufacturing, says these improvements are part of a long-term initiative to refine construction standards while responding to growing market expectations for durability and performance.

With an eye on environmental impact, R&C is also researching a new, slower-curing resin formula optimized for warm climates, set for possible deployment by late 2025. The company is additionally exploring localized hull temperature control systems to reduce the energy costs associated with factory-wide climate regulation during the build process.

These technical refinements are already being applied to newer models like the Leopard 46 and are expected to filter through the broader Leopard lineup in the months ahead.

Visit Leopard Catamarans for more information and their latest developments.

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What Is Resin Infusion—and Why It Matters in Boatbuilding

Also known as vacuum infusion, resin infusion is a widely used method in advanced composite construction, especially in the marine, aerospace, and automotive industries. The technique ensures strong, lightweight, and high-quality parts—an ideal match for the demands of performance cruising boats.

Here’s how it works:

1. Mold Preparation
   A rigid mold defines the final part’s shape and is carefully prepped with release agents.
   
2. Reinforcement Layup
   Dry fiberglass, carbon fiber, or other reinforcements are layered inside the mold.
   
3. Bagging
   A vacuum-tight film is sealed over the mold, forming a closed system.
   
4. Vacuum Application
   Air is removed using a vacuum pump, compressing the fiber layers and preparing them for resin.
   
5. Resin Infusion
   Liquid resin is drawn into the mold by vacuum pressure, saturating the fibers uniformly.
   
6. Curing
   The infused part is left to cure under vacuum, forming a solid, bonded composite.
   
7. Demolding
   Once cured, the part is removed from the mold—often with minimal surface finishing required.

Why it matters:

• Higher strength, lower weight: Consistent fiber-to-resin ratios produce structurally efficient parts.
  
• Fewer voids and defects: The vacuum process prevents air pockets and ensures full saturation.
  
• Cleaner and safer: Reduced resin waste and lower VOC emissions make this a more environmentally friendly method.
  
• Refined finish: Infused parts often need less post-production work, saving time and improving aesthetics.
  

In high-stakes applications like bluewater catamarans, where strength-to-weight ratio, durability, and long-term performance matter, this technique helps builders deliver reliable offshore vessels.

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