SERVICES
Builds Modifications Repairs
Success in our mission comes from a unified approach. As a team, we tailor every build, modification and repair to its exact specification, examining and optimising every detail. These principles define how we work and fuel our pursuit of perfection.
Design & Development
Our technical team delivers an integrated design approach that allows us to move seamlessly from creativity to manufacturability, ensuring that every concept is developed with real-world production in mind. Our systems are supported by design-driven workflows and rigorously developed SOP documentation, together with detailed construction-issue drawings that provide absolute clarity throughout the build process.
Tooling & Moulds
Our tooling capability combines multiple fabrication methods to deliver precise moulds tailored to each project’s geometry and production requirements.
Large, fair surfaces such as hulls and decks are engineered and fabricated in-house using high-stability wooden moulds. ensuring fast turnaround and full control over surface development. In some cases, to achieve localised accuracy, surface quality and efficient production, we may integrate CNC-machined HD foam sections into these wooden moulds.
For components with complex geometry or tight tolerances, we design and produce CNC-machined tooling in a range of high-density tooling board or aluminium. This provides excellent dimensional accuracy for low-volume, prototyping or low-medium production runs.
When required, we work with specialist machining partners to manufacture large CNC patterns/plugs for direct moulds, typically monolithic carbon fibre or fully machined composite poly and paste moulds.
Advanced Composite Processing
Our composite processing capability is built on rigorously developed SOPs, structured checkpoint documentation, and tightly controlled environmental conditions. Every component is manufactured under its own SOP, enabling real-time data logging, traceable sign-offs, and complete process transparency from start to finish.
All core materials, including foam cores, honeycomb Nomex and dry fibre reinforcements, are stored in climate-controlled environments. Prepreg materials are held in dedicated freezers to maintain resin stability and guarantee full shelf-life integrity. Lamination and core fit takes place in temperature and humidity-controlled cleanrooms that can are converted into large-format ovens for precise out-of-autoclave curing.
Process integrity is verified using advanced diagnostic tools, including ultrasonic leak detection to validate vacuum bagging, industrial borescopes for detailed honeycomb bond inspection, and high-precision digital vacuum gauges to monitor and record debulk pressure throughout the layup. Every component is subjected to aerospace-grade vacuum drop tests prior to cure or infusion.
We specialise and pride ourselves in out-of-autoclave processing and have a proven track record in producing exceptionally high-quality prepreg laminates with consistent fibre consolidation and extremely low void content. Each stage of production is documented and traceable.
Transparency and Traceability at Our Core
Core operations
Custom Yacht builds
We specialise in fully custom composite yacht builds, from high-performance racing platforms to defence and prototype vessels. We work in close collaboration with world-class naval architects and design teams, and we draw on extensive hands-on experience from the Volvo Ocean Race, IMOCA, and the America’s Cup. Each project is managed from the ground up through to sea trials.
Our background in advanced composite boatbuilding, combined with broad technical capability and a strong industry network, enables us to deliver not only a 'composite box' but fully equipped, ready-to-launch racing yachts and advanced prototype vessels.
Structural Components & High-visual Manufacturing
We pride ourselves on precision prepreg carbon layup for structural components and high-visual cosmetic panels used on Grand Prix racing yachts competing in the IMOCA, SailGP and Maxi Grand Prix Class. Using carbon fibre pre-impregnated with a controlled resin system, each layer is meticulously placed either as a monolithic or sandwich layup, vacuum-consolidated, and cured to deliver optimal stiffness-to-weight, repeatable quality, and race-proven durability. This advanced process achieves aerospace-grade performance and exceptional finish for the most demanding competitive environments.
Advanced infusion processing
We utilise vacuum infusion processing to manufacture high-integrity carbon and fibreglass composite structures with controlled fibre wet-out, optimised resin flow, and exceptionally low void content. Drawing on knowledge gained from the wind-power industry, our approach incorporates permeability modelling, optimised fibre-volume fractions, core-bonding strategies, and closed-mould consolidation techniques to deliver superior laminate quality and mechanical performance. This methodology is ideal for large, complex structures, such as yacht hulls and decks, or civil infrastructure components, where stringent weight targets, structural efficiency, and high-end finishes are essential.
Quality Control & Verification Systems
SR Structures operates a rigorous, multi-layered quality control system designed to ensure every component leaving our facility meets the highest standards of structural integrity, precision and finish. Our QC processes are embedded into every stage of production, from material preparation through to final inspection, and they are supported by advanced diagnostic technologies and formalised documentation. This ensures full traceability across every operation.
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