SH-Sep20-THIS Bieker hi res.qxp_S_H May Rob.qxd 23/07/2020 15:45 Page 42

At that stage evolution had been rigorous structural engineering methods to continuous but incremental and Scott saw the boat to make it as dependable and stiff an opportunity to take forward some of as possible for its weight. Knife, the latest configuration improvements in Scott and I pulled together a team that the boats and incorporate them in a brand included SoftBank Team boat- MARTINA ORSINI new no-compromise design that also took builder James Gell and Oracle Team USA advantage of some of the things that we design engineer Riley Dean to assist us in gunfight had learnt from our recent experiences in turning the boat into a real product. the Cup. Taking an excursion back into Throughout the next 12 months the core the world of high-performance skiffs after team was boosted by additional specialist When a leading skiff designer spending the previous three years almost FEA expertise from Thomas Hahn and who is equally renowned as exclusively working on foiling AC cata - Leopold Fricke from the composite design an America’s Cup innovator marans sounded like a nice way to wind and analysis firm Ixent, foil section analy- down from the Cup! sis from Hal Youngren and CFD analysis and structural engineer turns I had designed bits and pieces for Moths from Nico Rousselon to help us to develop his attention to the Moth class over the years – initially with innovative the design. the result is never going to be American Moth sailor Bora Gulari. That Pulling together a diverse, geographi- said, this was the first time I’d been given cally separated team for what was essen- anything less than fascinating the chance to design a complete package. tially a passion project was always going Our principal goal for the new boat was to be a challenge, but the enthusiasm and In the aftermath of the 2017 America’s evolutionary rather than revolutionary: interest from the team members, along Cup, as I was packing up our things to primarily to improve the aerodynamic effi- with persistent prodding by Scott himself, move back to Seattle after two years in ciency of the package and to increase the pushed the project along nicely. Boat #1 , longtime Moth sailor and Soft- righting moment by increasing the length launched at the end of July 2018 in New Bank Team Japan performance coach of the foil struts as well as increasing the Zealand, some 16 months before its debut Scott Babbage came over to discuss a new height of the hiking wings relative to the at the 2019 Moth Worlds in Perth. Moth project he had in mind. hull. In addition to this, I wanted to apply At launch interest and expectations for

42 SEAHORSE SH-Sep20-THIS Bieker hi res.qxp_S_H May Rob.qxd 23/07/2020 15:46 Page 43

Left: American sailor Scott Babbage was integral to creating the new Bieker Moth but his SailGP obligations led to pauses in development. However, with two of the new Bieker Moths in the top four at their first championship, world champion (Exocet) did later concede that out of the box the ‘straightline speed is impressive… lucky for me it’s not yet matched by the boat handling!’ While the latest Exocet package used by Slingsby is the product of five years of refinement for the immaculately executed (right) Mackay-built Bieker it’s still early days the boat were high. Over 50 deposits were speed involved refining the control system Mackay Boats in , which has placed within the first fortnight, with the linkages and getting the foil angles of the facilities and manpower to keep up challenge for James being how to both attack dialled in. In addition, the initial with orders. James Gell manages the Moth refine and problem solve the initial boat… front foil concept didn’t meet performance build team at the Mackay shop so there and then produce several years’ worth of expectations and so the team sought to has not been a loss of continuity in the forward orders at the same time. While the eliminate some of the variables by adapt- construction detailing of the boats. And prototype survived its initial launch in ing existing main foils to the longer Bieker we are continuing to improve the plat- Tauranga and sea trialling in Sydney, Moth struts. Meanwhile, Scott worked form, most recently by transitioning needless to say there were plenty of bugs to with CST Composites and Rob Green- from woven pre-pregs to ultra-lightweight be ironed out and a lot of refinement left to halgh from North Sails to develop a deck- spread tow pre-pregs in the hull, a new AP do before the boat was fully race ready. sweeping rig and sail that took full advan- main foil design which is adapted to the The boat itself was not without its tage of the clean new platform layout. recent increases in boat speed and a new, challenges. High-angled, small-area wings In August 2019 the whole concept more aerodynamic rudder pod. and long foils made it difficult for even started to hit its stride. Modifications to After that it looks as if there is room to experienced sailors to adapt to the change rig geometry, and the addition of some further improve the aerodynamics of the in handling characteristics. In fact, this dif- aerodynamic fairings, tipped the boat over rigs, especially now that the boat speeds ficulty made it hard at times to evaluate the edge. In the Sydney training group, upwind have broken into the 20s. Moths performance relative to other Moths. which included Tom Slingsby and Rob are interesting boats and a lot of fun! With Scott working in New Zealand Greenhalgh, Scott went from fighting hard with SailGP for the last few months of to having wheels. Over the next few Racing 2018, progress on the water slowed and months a mini America’s Cup of evolution The 2019 Worlds in Perth was the first the performance of the new boat remained occurred, with the group leap-frogging international event for the Bieker Moth. unclear. The potential was there, but so ahead each week with changes. By the All of the boats built over the previous were the doubts. Intense interest is a double- worlds in December the boats were regu- 18 months by LSF Composites and then edged sword for a developing concept in a larly seeing upwind boat speeds some 4kt Mackay Boats were competing, with boat- world where news gets around fast. faster than only a few years earlier. builder James Gell attending in support. Most of the work to get the boat up to Our new Moths are now being built by In Perth’s strong wind conditions the ᮣ

SEAHORSE 43 SH-Sep20-THIS Bieker hi res.qxp_S_H May Rob.qxd 23/07/2020 15:46 Page 44

Fig 1 Fig 2 Fig 3

Figure 1: using a (top-end weight) sailor of 100kg all the major load cases were then considered in the optimisation process. Figure 2: rack sizing before optimisation (blue) and after optimisation (orange). Figure 3: property optimisation. Result of unidirectional laminate thickness (mm). Figure 4: final check – stress distribution is demonstrated across the rack using an envelope of the worst overall load cases. Figure 5: final check of stress distribution Fig 4 Fig 5 on hull – envelope of the worst load cases low aero drag of the Bieker gave them a Matthew Chew in eighth. Six Biekers in maximum benefits. Yet the motivation to crucial upwind speed advantage. Out of the top 15 – more than any other design. use optimisation is compelling and, in the blocks the boats would quickly and Paul Bieker, Seattle mechanical applications that we are focus- reliably establish themselves in the leading ing on here, weight saving and/or stiffness group, which then paid dividends on a Structural design and optimisation increases can be achieved without sacrific- consistent racecourse. Despite their strong Nowadays the use of numerical simulation ing the safety of the structure. And today

JOSHUA MCCORMACK wind drag advantage the Bieker also won in the development of yacht structures is there are more types of optimisation avail- the lightest race of the final series on the very advanced as can be seen in the multiple able, depending on the development stage, last day, showing the platform hadn’t articles on various yacht projects in this design freedom and objectives. painted itself into a performance corner. journal. Unfortunately, however, simula- With Paul’s almost emotional connec- In hindsight the results for the boat were tion is often only used late in the process, tion to structural design it was obvious remarkable given their relative newcomer to check the final configuration for that we had to transfer these methods from status among strong, established rivals. strength and stiffness. What we have done the America’s Cup into the Moth project. While Tom Slingsby dominated the during development of the Bieker Moth is Once the decision was made to take this Worlds in his Exocet, Scott Babbage was push these simulation methods to the next path we took step after step from the con- able to equal his score in the Nationals and step of numerical optimisation. ceptual design to the final detailing, using placed fourth in the Worlds. Kyle Lang- Despite the widespread availability of suitable and different optimisation types in ford finished second overall, with this technology it is seldom used to its every stage.

44 SEAHORSE Pg 45.qxp_Layout 1 24/07/2020 16:24 Page 1

Exquisite use of the finest high modulus materials by Mackay Boats led by SoftBank’s AC50 builder James Gell has delivered an end product that would look equally at home in a major design museum as on – and above – the water. An unusual amount of design and engineering brainpower to go into producing an 11-foot foiling dinghy but someone still needs to turn all of that thinking into a boat

Setting up the problem the optimiser was also allowed to modify Final step: validation One of the advantages of numerical opti- rack beam height. In Figure 2 we see the The optimisation process shown here (for misation is the simultaneous considera- configuration before and after the optimi- the rack structure) is only a typical extract tion of multiple load cases including vary- sation. It then needed Paul’s expertise – of what we have undertaken on the rest of ing loads and boundary conditions. In and therefore still some human inspiration the boat. Hull, rudder, main foil and so on Figure 1 (opposite) the main load cases – to interpret these results and combine all underwent a similar procedure with the considered in the optimisation process are this with other design requirements of the objectives individually set in each case shown. One can easily imagine that a Moth (ergonomics, aerodynamic drag, (weight, deflection etc). designer is capable of focusing on one fitting positions and so on). As on other projects the final step is load case and getting reasonable solutions checking the structural response of the for strength and stiffness, but simultane- Detailing: laminate scantlings Moth with every detail incorporated in it. ously focusing on all load cases is an Next step in the optimisation process is the Figures 4 and 5 show the stress envelope impossible task. Here the computer is a property or thickness optimisation. Here on the current rack and hull over all load great help! laminate thicknesses, layer orientation and cases – a very evenly distributed stress material types are optimised again under distribution points to a very efficient First step: sizing the objective of minimum weight. The structure. The first optimisation task we tackled was optimisation delivers, for example, a distri- The methodologies described here are the geometric sizing of the rack: what is bution of the unidirectional fibres in a pre- readily available – all that is required are the optimum aspect ratio of the rack selected high modulus material (it also designers willing to incorporate them into beams and how are these distributed to reveals the lay-up for the other directions). the design process. achieve maximum stiffness without break- Figure 3 shows such a distribution across Leopold Fricke and Thomas Hahn, ing? As the objective is minimum weight the rack. Ixent, Munich K

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the company’s chief executive. ‘We threw ourselves into the fire when Print Term Price Add Digital we could have hidden. We knew this would be a huge project to take our kit to the next level. The fact that both teams are so happy makes the company very proud. The great thing for us now is that this technology is available for consumers to buy.’ Milczarczyk adds: ‘It’s really satisfying to have got through it, despite a few moments where it felt like we were struggling, with the brand reputation at stake. But our for 20% More teamwork was good, lifting each other when we needed to, and the inspiration from the race teams was huge. Their task was to win and so was ours! It’s been an incredible journey and it won’t stop here.’

Seeing through white water On a boat as relentlessly wet as the Volvo Ocean 65, visibility can be extremely challenging. Zhik helped hottest conditions all in the course solve that problem with the of one leg. development of its Hydrovision visor, Thank you! Merçi! Thank you!!! ‘One problem all teams had was which proved a big hit with the getting something that worked in hot helmsmen and helmswomen on the and humid climates, while being fire- two Zhik-outfitted boats. There was so much new to celebrate about Dongfeng’s wonderful victory in 1 Year (12 issues) €90.00 €108.00 hosed by water on deck,’ Molloy The visor was part of an integrated continues, ‘and trying to find the system of clothing designed to be as the 2017-2018 Volvo Ocean Race and skipper Charles Caudrelier was balance between comfort and still multi-purpose and adaptable as refreshingly quick to give credit where it was due… remaining waterproof enough to possible, as Milczarczyk explains. survive 20-plus days at sea. Most ‘The adaptive hood system that ‘Thanks for your support and all impressed by the commitment from Above: AkzoNobel helmsman and sail Thank you! Merçi! Thank you!!! of our development of the layering won the Dame award was a direct you have done to improve our gear! Zhik. ‘You guys never give up. Your ‘There is no trimmer Luke Molloy says: ‘We system was done prior to the start result of our design team fixing a We all have been impressed,’ said resilience is the same as our team. escaping the realised that the race was one-and-a- There was so much new to celebrate about Dongfeng’s wonderful victory in Thank you! Merçi! Thank you!!! and I’m happy to report that we problem, specifically that while each Charles Caudrelier to his partners, We almost feel obliged to use all the brutality of half times the length of any previous the 2017-2018 Volvo Ocean Race and skipper Charles Caudrelier was were all toasty warm in the this boat.’ member of the crew could only take Zhik, when he and his Dongfeng new stuff – we feel that we owe it to Volvo Ocean Race and we allocated refreshingly quick to give credit where it was due… Southern Ocean.’ one smock or jacket with them on Competing Race Team became the first China- you after all the work you have put enough garments per sailor to get ‘Thanks for your support and all impressed by the commitment from There was so much new to celebrate about Dongfeng’s wonderful victory in Rio 2016 and the America’s Cup in For Zhik’s The race was an opportunity for board, they really needed several in the Volvo Above: AkzoNobel helmsman and sail flagged team to win the biggest in,’ he said. Ocean Race through the extra distance. Volvo you have done to improve our gear! Zhik. ‘You guys never give up. Your ‘There is no trimmer Luke Molloy says: ‘We ZHIK Bermuda 2017, were competing in design team, intensive testing and feedback in different types of hood,’ he says. ‘Our We all have been impressed,’ said resilience is the same as our team. escaping the realised that the race was one-and-a- the 2017-2018 Volvo Ocean Race and skipper Charles Caudrelier was offshore prize in sailing, the Volvo While traditionalists might bemoan is a feat of Ocean Race sailors are extremely Charles Caudrelier to his partners, We almost feel obliged to use all the brutality of half times the length of any previous their first Volvo Ocean Race. the Volvo an extreme offshore laboratory, says new adaptive hood system gave the this boat.’ Ocean Race Ocean Race. the use of one-design Volvo Ocean extreme tough on the gear so we knew that Zhik, when he and his Dongfeng new stuff – we feel that we owe it to Competing Volvo Ocean Race and we allocated refreshingly quick to give credit where it was due… However, as Team AkzoNobel Bart Milczarczyk, Zhik’s global head sailor a zip-on choice of hood with endurance Race Team became the first China- you after all the work you have put in the Volvo enough garments per sailor to get was ‘an They say it’s the little things that 65s in the past two editions of the we would need a few sets per sailor. flagged team to win the biggest in,’ he said. Ocean Race through the extra distance. Volvo

skipper Simeon Tienpont points out, of design. The Zhik team spent time Hydrovision visor, Superwarm RACE OCEAN BLAKE/VOLVO JAMES opportunity and choosing offshore prize in sailing, the Volvo While traditionalists might bemoan is a feat of Ocean Race sailors are extremely 2 Years (24 issues) €175.00 €210.00 make the difference at the top level race, the technical apparel industry ‘We also worked with Zhik on ‘Thanks for your support and all impressed by the commitment from Above: AkzoNobel helmsman and sail ‘Zhik is pretty new in the ocean for intensive with the crews at the stopovers, neoprene balaclava or a lightweight, the right kit is Ocean Race. the use of one-design Volvo Ocean extreme tough on the gear so we knew that of sailing, and yes, it’s a cliché, but has benefited enormously from this refining the zip-on hood and other They say it’s the little things that 65s in the past two editions of the endurance we would need a few sets per sailor. you have done to improve our gear! Zhik. ‘You guys never give up. Your ‘There is no trimmer Luke Molloy says: ‘We racing scene. But I knew the Zhik testing and undertaking thorough garment water-repellent Avlare balaclava. crucial for RACE OCEAN BLAKE/VOLVO JAMES and choosing escaping the after that sensationally nail-biting one-design era. Sailors are no success. The headwear to try and reduce the total make the difference at the top level race, the technical apparel industry the right kit is ‘We also worked with Zhik on We all have been impressed,’ said resilience is the same as our team. realised that the race was one-and-a- guys from the America’s Cup and feedback in inspections, gaining vital feedback The Isotak X Ocean Smock and of sailing, and yes, it’s a cliché, but has benefited enormously from this crucial for refining the zip-on hood and other Charles Caudrelier to his partners, We almost feel obliged to use all the brutality of half times the length of any previous the stuff they did for us then. They an extreme and co-ordinating a rapid response its Adaptive Hydrovision Hood would climax in the Volvo Ocean Race, different from any other professional notoriously number of garments needed by after that sensationally nail-biting one-design era. Sailors are no success. The headwear to try and reduce the total this boat.’ offshore wet, exposed climax in the Volvo Ocean Race, different from any other professional notoriously number of garments needed by Zhik, when he and his Dongfeng new stuff – we feel that we owe it to Volvo Ocean Race and we allocated always put in the extra effort to make to trial new ideas. come into their own in the harsh could anyone argue otherwise? athletes – they will look for an edge making them multi-purpose, covering could anyone argue otherwise? athletes – they will look for an edge wet, exposed making them multi-purpose, covering Competing laboratory’. and brutally and brutally After 45,000 nautical miles wherever they can find it. So if they’re a wide range of conditions.’ After 45,000 nautical miles wherever they can find it. So if they’re a wide range of conditions.’ Race Team became the first China- you after all the work you have put in the Volvo enough garments per sailor to get it right for us to fit properly – and to With two By no means was it all plain conditions of the Southern Ocean. uncomfort- uncomfort- around the world, the winning margin not allowed to tinker with their one- Considering that this was the around the world, the winning margin not allowed to tinker with their one- able ride Considering that this was the flagged team to win the biggest in,’ he said. Ocean Race through the extra distance. Volvo keep us warm and dry.’ teams in the sailing. Like all innovation and Team AkzoNobel’s helmsman, able ride on the decisive final leg came down design boats, they’ll turn their aboard the Australian brand’s first foray into the offshore prize in sailing, the Volvo While traditionalists might bemoan is a feat of Ocean Race sailors are extremely Zhik had carried out extensive race wearing development cycles inevitably Nicolai Sehested, described the visor on the decisive final leg came down design boats, they’ll turn their aboard the Australian brand’s first foray into the to 17 minutes, give or take a few attentions elsewhere. VO65 one Volvo Ocean Race, it might have extreme seconds. It had been a brutal, Improvements in the clothing were design boats seemed quite a risk going away from Ocean Race. the use of one-design Volvo Ocean tough on the gear so we knew that laboratory testing before releasing Zhik kit and some concepts had to go back to as ‘a godsend’. to 17 minutes, give or take a few attentions elsewhere. VO65 one Volvo Ocean Race, it might have relentless race around the planet. an obvious place to focus, particularly is a punishing the proven alternatives. Not that Zhik endurance providing a Caudrelier knew that his crew bearing in mind the exposed cockpit test bench for is without pedigree, however. Since They say it’s the little things that 65s in the past two editions of the we would need a few sets per sailor. its offshore gear to the sailors. But the drawing board for refinement. There are several unique elements seconds. It had been a brutal, Improvements in the clothing were design boats seemed quite a risk going away from clothing as

JAMES BLAKE/VOLVO OCEAN RACE OCEAN BLAKE/VOLVO JAMES and choosing would have to keep on improving constant is a punishing of the Volvo Ocean 65 and the well as crew the 2004 Olympic Games in Athens, make the difference at the top level race, the technical apparel industry the right kit is ‘We also worked with Zhik on the company knew that real-world ‘We had our butt kicked a few in the design and functionality of relentless race around the planet. an obvious place to focus, particularly the proven alternatives. Not that Zhik from leg to leg, and the demanding constant fire-hosing of white water Zhik has powered many athletes to stream of test bench for of sailing, and yes, it’s a cliché, but has benefited enormously from this crucial for refining the zip-on hood and other feedback would be vital to developing times,’ Milczarczyk recalls frankly, Zhik’s Adaptive Hydrovision hood Caudrelier knew that his crew bearing in mind the exposed cockpit is without pedigree, however. Since Frenchman expected the same of across the deck. There is no escaping numerous medal winning feedback, the clothing as his partners. the brutality of this boat. performances, not least the Kiwi after that sensationally nail-biting one-design era. Sailors are no success. The headwear to try and reduce the total the clothing further. ‘which is ultimately a good thing. and collar system: company’s would have to keep on improving of the Volvo Ocean 65 and the well as crew the 2004 Olympic Games in Athens, Bruno Dubois, the team manager The other factor was just how long duo Pete Burling and climax in the Volvo Ocean Race, different from any other professional notoriously number of garments needed by ‘Due to the wetness of the race,’ development Our response was to dig deep and It can be completely removed, from leg to leg, and the demanding constant fire-hosing of white water Zhik has powered many athletes to of the Dongfeng Race Team, was also this edition of the race was, as Team who, after winning Olympic gold in wet, exposed could anyone argue otherwise? athletes – they will look for an edge making them multi-purpose, covering Molloy says, ‘particularly in the first cycle was work harder. Once we commit to a transforming the Ocean Smock to Frenchman expected the same of across the deck. There is no escaping numerous medal winning 68 SEAHORSE After 45,000 nautical miles and brutally week of leg two, we worked with Zhik accelerated. new partnership we don’t stop until a dry smock in milder conditions 3 Years (36 issues) €246.00 €295.20 wherever they can find it. So if they’re a wide range of conditions.’ uncomfort- The Dongfeng his partners. the brutality of this boat. performances, not least the Kiwi around the world, the winning margin not allowed to tinker with their one- Considering that this was the on a few concepts that we tried on we succeed.’ Inevitably, there were The hood features a clear, rigid able ride and Akzo Bruno Dubois, the team manager The other factor was just how long 49er duo Pete Burling and Blair Tuke on the decisive final leg came down design boats, they’ll turn their aboard the Australian brand’s first foray into the later legs. I can't give away many Nobel teams some intense times with the visor to protect the face from spray, of the Dongfeng Race Team, was also this edition of the race was, as Team who, after winning Olympic gold in to 17 minutes, give or take a few attentions elsewhere. VO65 one Volvo Ocean Race, it might have details because we could see these were a great development unit at full stretch for which negates the need for goggles. seconds. It had been a brutal, Improvements in the clothing were design boats seemed quite a risk going away from features in their ranges of clothing source of many months, especially as the An integrated hood/visor (rather than 68 SEAHORSE relentless race aro nd the planet b i l t f ti l l is a punishing th lt ti N t th t Zhik W i tt tt inspiration ‘ l’ l l f d t helmet/goggles) means far more 5 Years (60 issues) €383.00 €459.60

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