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Diab’s Divinycell HM Foam Used in Constructing Mayla 44, a New Ultra-High Performance Electric Power Boat November 21 2022

2022 Lucintel Composites Market Insights, November 21, 2022

Due to launch in early 2023 in Dubai, the Mayla 44 is a radical 44 footer that blends classic styling elements with a state-of-the-art composite construction and electric drivetrain. Designed around the patented Petestep hull technology, the Mayla uses uniquely shaped deflectors to push water downwards and to the stern of the yacht, generating energy savings of up to 35% as well as reducing slamming and increasing passenger comfort.
Even with its novel hull design, the Mayla 44’s 70 knot plus top speed required an extremely lightweight construction in the form of a carbon fiber full-sandwich composite structure. With outright weight reduction a priority, Diab supplied Divinycell HM 80 and 130 cores in a range of thicknesses for the deck, internal structure and the complete hull surface including the hull bottom. Epoxy prepregs from Nova’s sister company Notus Composites will be combined with a range of woven, stitched multiaxial and unidirectional carbon fiber reinforcements on either side of the Divinycell HM cores.
Divinycell HM cores have been extensively evaluated in previous Nova projects, with the company also completing a program of mechanical testing to validate the properties of the new Mayla 44 laminates. In-house composite tooling produced from CNC milled master plugs has been perfected and the NOVA technicians are scheduled to begin prepreg lay-up and positioning of the first Divinycell core sections in November.
Christopher Gelsdorf, co-Founder of Mayla Yacht, said, “The lightweight prepreg carbon fiber sandwich construction we use for the Mayla 44 enables a hull weight of only 1.35T (versus more than 4T for traditional high-performance yachts) creating less resistance and less drag.”

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