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The key to a World Cat catamaran’s uniquely superior performance is the hull design, which needs to take into account not only the hydrodynamics of hull shape, but also the friction-reducing VectorFlo® tunnel shape, and the precise shape and size of the planing surfaces – all while balancing weight and strength for optimal performance in a wide array of conditions For optimal performance, structural integrity and precise fit, all World Cat hulls and decks are designed using the industry’s most sophisticated CAD/CAM 3D modeling software (which is also used for aeronautic design and was used to develop the Mars Rover). Dozens of iterations of deck layout and dimensions are developed for each boat as our designers seek the solution that best meets our customers’ needs Once a design is near completion, a full-scale mock-up is built so that user ergonomics can be evaluated and final adjustments made. These adjustments are incorporated into the final computer design, which now includes critical unseen elements such as wiring, plumbing and drainage When the design is finalized and signed off, every part is computer modeled; plugs and then molds can then be precision tooled. Once these plugs and molds are complete, the boat is ready to be built. A great design is fully brought to life by construction with the highest quality materials, which need to balance weight, strength and durability. World Cat’s extensive building experience directs us to use only the best materials for the purpose The first step in building a boat with a beautiful, smooth, durable hull exterior is using the highest quality gel coat and applying a 100% vinylester barrier coat to the mold. The gel coat provides a beautiful surface that will last for years, and the barrier coat protects against blistering and enhances the cosmetic finish of the gel To create a powerful barrier between the gel coat surface and heavier glass material, a fine mat fiberglass “skin coat” is laminated into the hull before the build begins Bi-directional and tri-directional knitted fiberglass cloth, pre-cut by hand into shapes precisely engineered for each boat model, is applied onto the mold by hand to assure a stronger, more durable laminate To add greater strength to hull bottoms, layers are overlapped in water shock areas and a thick layer of 36-ounce woven roving cloth is laminated from chine to chine To bring you years of unmatched endurance, World Cat fabricates its structural bulkheads and stringers from high density composite materials that are impervious to water absorption and rot For enhanced flotation and sound and thermal insulation, strategic cavities are filled with foam after the stringers and bulkheads are glassed into the hull To create a rugged transom, high-density composite is bonded to the transom and reinforced with durable aluminum plates in engine mount areas Only the finest materials are used, so our stainless steel hardware is fabricated from 316 grade stainless steel to better withstand the saltwater environment.