SEABOAT · Project

Lighter, Cheaper, Zero-Emission Boat Hulls Made with Advanced Composite Technology

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Imagine boat hulls are still made the old-fashioned way — heavy, expensive, and full of toxic fumes during production. This team took a manufacturing trick originally designed for aerospace and wind turbines — a dry powder epoxy process — and adapted it for building boats. The result is a hull that's 45% lighter and 30% cheaper, which means you can pack in more batteries and finally make an electric boat that actually competes with a diesel one. Think of it like what Tesla did for cars, but for the water.

By the numbers

30%

Hull cost reduction vs conventional manufacturing

45%

Hull weight reduction

60%

Operational cost reduction vs fuel-powered boats

€45m

Projected cumulative revenue 2021-2023

260

Projected jobs created

$20bn

Estimated global electric boat market by 2027

Emissions in operation

EUR 1,645,000

EU funding received

The business problem

What needed solving

Recreational boat manufacturing still relies on outdated processes that are expensive, produce heavy hulls, and emit toxic VOCs — and these methods will not meet upcoming environmental legislation. The resulting hull weight makes electric propulsion impractical for most boats, keeping the marine industry locked into fossil fuel engines while cars and trucks go electric.

The solution

What was built

The team built and tested a Composite Powder Epoxy Technology (C-PET) manufacturing process for boat hulls, proving superior mechanical properties versus competitors' materials and demonstrating that joints between hull sub-components outperform conventional glued joints. This was demonstrated in an advanced electric boat design incorporating the C-PET hull.

Audience

Who needs this

Recreational boat builders looking to cut hull production costs and meet VOC regulationsElectric boat startups needing lighter hulls for competitive battery rangeMarine composite fabricators seeking to replace wet layup processesBoat fleet operators wanting to switch from fuel to electric propulsionWind energy or aerospace composite companies looking to enter the marine market

Business applications

Who can put this to work

Recreational boat manufacturing

SME

Target: Boat builders and yacht manufacturers

If you are a boat manufacturer struggling with rising material costs and tightening VOC emission regulations in your production facility — this project developed the C-PET composite manufacturing process that cuts hull production costs by 30% and eliminates toxic Volatile Organic Compounds entirely. The resulting hulls are 45% lighter, opening the door to electric propulsion designs that reduce operational costs by 60%.

Electric marine propulsion

SME

Target: Electric boat and marine drivetrain companies

If you are an electric boat company limited by battery range and hull weight — this project proved that powder epoxy composite hulls weigh 45% less than conventional alternatives. That weight saving translates directly into extra battery capacity and extended range, making battery-powered boats competitive with fuel-powered ones for the first time. The electric boat market is estimated to reach $20bn by 2027.

Advanced composites manufacturing

mid-size

Target: Composite fabricators serving marine, wind energy, or aerospace sectors

If you are a composites manufacturer looking to diversify into marine applications — this project demonstrated that Composite Powder Epoxy Technology (C-PET), originally developed for aerospace and renewable energy, transfers successfully to boat hull production. The process eliminates VOC emissions during manufacturing and delivers laminates with superior mechanical properties compared to competitors' materials.

Frequently asked

Quick answers

How much does this technology reduce production costs?

According to the project data, C-PET lowers the cost of boat hulls by 30% compared to conventional manufacturing. Operational costs for the resulting electric boats are reduced by 60% versus fuel-powered alternatives. These figures come directly from the project objectives.

Can this scale to industrial production volumes?

The technology was developed under an SME Instrument Phase 2 grant (EUR 1,645,000), which specifically targets commercialization and scale-up. ÉireComposites projected cumulative revenue exceeding €45m and 260 jobs from 2021-2023, indicating serious commercial-scale ambitions. The C-PET process was originally conceived for aerospace and renewable energy — sectors that already operate at industrial scale.

What is the IP and licensing situation?

The C-PET technology was developed by ÉireComposites Teoranta, an Irish SME specializing in composites manufacturing. Based on available project data, the IP likely resides with ÉireComposites as the coordinating SME. Licensing or partnership terms would need to be discussed directly with the coordinator.

Does this meet upcoming environmental regulations?

The project explicitly states that current hull-manufacturing processes will not meet new legislation. C-PET eliminates toxic Volatile Organic Compounds (VOCs) entirely during production and delivers zero-emission boats in operation. This positions adopters ahead of tightening environmental rules in marine manufacturing.

What has been physically tested and proven?

Deliverables confirm proven materials benchmarked against competitors, demonstrating superior mechanical properties for powder epoxy laminates. Joint strength between hull sub-components was tested and shown to be superior to conventional glued joints. The technology was demonstrated in an advanced electric boat prototype.

How does this integrate with existing boat manufacturing?

C-PET replaces traditional wet layup or infusion processes used in hull manufacturing. Based on available project data, the process uses dry powder epoxy rather than liquid resins, which simplifies handling and eliminates the need for VOC extraction systems. The consortium is 100% industry with two SME partners, suggesting practical manufacturing focus.

Consortium

Who built it

This is a lean, industry-only consortium of 2 SME partners, both based in Ireland, with zero university or research institute involvement. The 100% industry ratio and SME-2 funding scheme signal that this is a commercialization play, not a research exercise. The coordinator, ÉireComposites Teoranta, is a composites manufacturing specialist — they built this technology to sell it, not to publish papers about it. The tight two-partner structure means faster decision-making but limited geographic reach across European markets.

EIRECOMPOSITES TEORANTACoordinator · IE

How to reach the team

ÉireComposites Teoranta, Ireland — composites manufacturing SME. Use SciTransfer's matchmaking service for a warm introduction.

Order a report on this consortium See EIRECOMPOSITES TEORANTA profile →

Next steps

Talk to the team behind this work.

Want to explore licensing C-PET for your boat manufacturing line or integrate lighter hulls into your electric marine products? SciTransfer can arrange a direct introduction to the technology team. Contact us to discuss next steps.

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