Manufacturing of our boats

Welcome to the immersion in the process in The manufacture of carbon fiber rowing boats at Falcon Racing

Carbon fiber rowing boats are today the reference for competitors and performance enthusiasts. Light, rigid and designed with extreme precision, they optimize the glide on the water and improve the transmission of the power of the rowers.

The Falcon Racing company, recognized for its expertise in the manufacture of high-performance hulls, follows a rigorous process, from design to delivery.

Let's discover together the key stages of manufacturing a carbon fiber rowing boat.

1. Design: between engineering and innovation

Before even starting the manufacturing, everything begins with a technical study and advanced design work. The objective is to create a hull offering a perfect balance between lightness, rigidity and hydrodynamics.

Modeling and design

Using 3D modeling software, Falcon Racing engineers analyze hull shapes, optimize weight distribution, and test different carbon fiber configurations to maximize performance on the water.

Tank testing and digital simulations

Before manufacturing, hydrodynamic simulations are performed to ensure minimal drag and optimal stability. Some prototypes may be tested in tanks or in real conditions to adjust the final details of the design.

2. Manufacturing: high-precision carbon fiber assembly

Shaping the hull

Manufacturing begins with vacuum molding. The carbon fiber is laminated in a pre-designed mold, then impregnated with epoxy resin to ensure exceptional strength while maintaining minimal weight.

Choice of materials: Falcon Racing favors high-quality carbon fiber, combined with honeycomb structures to optimize rigidity without weighing down the boat.

Vacuum technique: Once the stratification is complete, the mold is placed under vacuum to remove air bubbles and ensure an even distribution of the resin.

Passage in autoclave

After molding, the hull is placed in an autoclave, a pressurized oven that heats the resin to a high temperature. This process allows optimal polymerization of the carbon fiber and reinforces the mechanical resistance of the boat.

3. Painting and finishing: a tailor-made final touch

Once the boat is assembled, it goes through the painting and finishing workshop. Falcon Racing offers personalized colors as well as specific designs according to the requests of clubs and competitors.

Painting process

The hull is first sanded and prepared to ensure perfect adhesion of the paint.

A primer undercoat is applied to guarantee a smooth and even finish.

The paint is then sprayed in a controlled booth, with special lacquers resistant to UV and maritime conditions.

A high-strength varnish is applied to protect the hull and give it its final shine.

Each boat then goes through a meticulous quality control where all the finishes are inspected to ensure an impeccable finish and maximum durability.

4. Delivery: safe transport to the rowers

Once the boat is finished, it is carefully packed and prepared for shipping. Falcon Racing offers different transport solutions to ensure safe delivery:

Transport by trailer: For large-scale deliveries, particularly for clubs and federations.

Personalized delivery for athletes: Some competitors can collect their boat directly from the workshop.

Assembly assistance and final adjustments: Support can be offered to adjust the last details before the first launch.

Conclusion: precision at the service of performance

The manufacture of a carbon fiber rowing boat is a complex process that combines cutting-edge engineering, precision craftsmanship and technological innovation. Using high-quality materials and advanced techniques, Falcon Racing delivers exceptional boats, designed to offer the best in terms of performance and durability.

Whether for a club, a professional athlete or an enthusiast, each boat that leaves the Falcon Racing workshops is the result of unique know-how, guaranteeing an unrivaled rowing experience on the water. 🚣‍♂