Lab 02
Hull Engineering Studio
Digital simulation, structural intelligence, custom hull design
The hull is the backbone of any inflatable SUP. It must be light enough to glide efficiently, strong enough to handle rocky shorelines, and rigid enough to convert every paddle stroke into forward motion. At Afarer, our Hull Engineering Studio combines advanced CAD modelling, finite element analysis (FEA), and decades of practical board-design experience to deliver hulls that are optimised for their intended discipline — not generic shapes adapted from a catalogue.
Where strength meets hydrodynamics
We work with three primary construction platforms — reinforced drop-stitch PVC cores, hand-laid fibreglass laminates, and rotationally moulded polyethylene — and have the engineering capability to design, simulate, and validate each one in-house.
Design tools and standards
Our digital engineering environment includes:
| Capability | Software / Tool | Application |
|---|---|---|
| 3D parametric modelling | SolidWorks Professional | Hull surface, rail and stringer reinforcement, deck layout, gear-mount points |
| Finite element analysis | ANSYS Mechanical & LS-DYNA | Stress mapping, modal analysis, crash/impact simulation |
| Computational fluid dynamics | Ansys Fluent / Star-CCM+ | Hydrodynamic drag prediction, trim optimisation |
| Laminate engineering | ESAComp / CADEC | Fibreglass layer stacking, core selection, weight estimation |
| Mould flow simulation | Moldex3D | Rotomoulding wall-thickness prediction |
Our engineering workflow
Every hull design, whether it is a standard model or a fully custom project, follows a rigorous five-stage process:
- Concept & requirements gathering — We meet with you to define rider weight and payload, speed envelope, water-state capability, transport requirements, and any special mission equipment (deck mounts, cargo tie-down positions, accessory integration).
- 3D surfacing & hydrostatic calculation — The hull form is modelled in SolidWorks and checked for hydrostatic stability, volume distribution, and righting moment using built-in analysis tools.
- Structural FEA — Load cases are defined: static (rider + gear), dynamic (wave-landing impacts at 5g), and grounding (striking a rocky shoreline at 3 m/s). Stress contours are reviewed; safety factor ≥ 2.5 is mandatory.
- CFD drag optimisation — The hull is simulated at three loading conditions and five speeds. Wetted surface area, trim angle, and residual resistance are iteratively reduced.
- Design review & release — The complete engineering package (3D model, FEA report, CFD report, weight estimate, ply book) is reviewed by our senior engineer before release to the prototype workshop.
FEA Stress Distribution — Touring SUP Hull (Reinforced Drop-Stitch)
Customisation: your hull, your rules
No two paddlers have identical requirements. A fishing SUP needs a wide, stable planing hull; a touring board needs a displacement hull that maximises glide; a surf SUP needs responsive rails and tuned rocker. We do not force your application into a pre-existing hull shape. We design from your specification upward.
Examples of recent custom hull engineering projects:
- A stretched-length touring SUP for a Caribbean eco-tour operator, with a reinforced bow for beach landings (+15 % rail thickness).
- A high-visibility patrol SUP for a harbour authority, with integrated gear mounts and tactical rails.
- An expedition touring SUP for a rental fleet, with reinforced rails and extra cargo tie-downs.
Our engineers
The studio is led by a senior engineer with 14 years of experience in high-performance board design, supported by two mechanical engineers specialised in FEA and CFD. All three hold advanced degrees in marine or mechanical engineering from internationally recognised universities. The team publishes regularly in industry journals and presents at international conferences on high-performance paddle-sport engineering.
Partner with us on your next hull
From the first concept sketch to the final stress report, our Hull Engineering Studio is your partner in creating a board that is not just built — but engineered. We invest the simulation hours upfront so that every weld, every laminate layer, and every curve of the hull is there for a reason.
Whether you need a minor modification to an existing model or a completely clean-sheet design, we are ready to discuss your requirements.
Start your hull design consultation
Tell us about your mission profile and we will propose an engineering path.
Contact our engineering team