Fabrication Overview

At Competition Composites Inc. (CCI), the fabrication process is driven by a deep understanding of materials, structural integrity, and performance. Every component is built to balance strength, weight, durability, and cost, ensuring optimal performance for its intended marine application.

Materials and Construction

CCI utilizes a combination of epoxy resin systems with either fibreglass or carbon fibre reinforcement, depending on the needs of the project. Epoxy resin is selected for its superior mechanical properties and resistance to water absorption, ensuring long-term durability in marine environments.

High-strength foils and components are constructed using vacuum bagging techniques, which provide excellent fibre-to-resin ratios and structural consistency. For parts that require additional stiffness without added weight, CCI integrates core materials such as foam or wood. These sandwich constructions are carefully engineered to meet the specific load requirements of each application.

Structural Considerations

Every part produced by CCI is designed with a clear understanding of the forces it will encounter. Bending, shear, and torsional loads are all evaluated to ensure the final product performs reliably. Reinforcement is placed where it is most effective, and transitions between materials are carefully managed to avoid weak points.

In rudders and foils, for example, the core is shaped to precise specifications before being sheathed with multiple layers of fibreglass or carbon fibre. Shafts and tangs are bonded into the structure with high-strength epoxy and reinforced to prevent movement under load. Each component is finished with durable coatings and faired to minimize drag.

Quality Control and Precision

All fabrication is carried out in CCI’s Arnprior facility, where temperature and humidity are monitored to maintain optimal curing conditions. The team uses templating, jigs, and CNC-cut components to ensure repeatability and accuracy across projects. Every part undergoes visual and mechanical inspection before it is approved for delivery.

Performance-Driven Results

With over two decades of experience in composite marine manufacturing, CCI understands what sailors and builders require. The fabrication methods used are not only based on best practices in the industry but are also refined by years of real-world performance feedback from competitive sailors and long-term clients.

From concept to completion, CCI’s fabrication process is engineered to deliver consistent, reliable, and race-proven results.