Offshore Spars are a company that specialize in composite masts for boats and marine manufacturing that includes crafting carbon fiber spars for sailboats. The site is based in Chesterfield, Michigan and covers around 40,000 square feet of land. This facility and its features are responsible for crafting high-quality, durable structures that withstand harsh marine environments.
Within the shop, Offshore Spars possesses a sophisticated array of cutting-edge technologies. The Autometrix AutoCut System ensures that every piece of material is cut with exacting accuracy. This allows the team to navigate complex projects, streamlines the production process and guarantees consistent quality. Furthermore, it helps to minimize waste while maximizing efficiency.
Once the materials are meticulously cut, they undergo a transformative process within the autoclaves. These high-pressure, high-temperature chambers, ranging in size and capacity, are at the core of Offshore Spars' manufacturing capabilities. By carefully controlling the temperature, pressure, and atmosphere, the autoclaves cure the composite materials, resulting in structures that are both lightweight and incredibly strong.
There is a choice of two autoclaves in the facility, each designed to optimize the curing process for carbon fiber components. The smaller autoclave, equipped with 30' x 90' sliding tables and a rapid-cooling chiller, is ideal for smaller parts and rapid turnaround times. The larger autoclave, a massive 100' x 12' tapered machine, is capable of curing larger, more complex structures. Both autoclaves operate at a maximum pressure of 100 PSI and temperature of 450°F, and can be purged with either nitrogen or air to create a controlled curing environment.
Offshore Spars' fabrication capabilities are equally impressive. Their state-of-the-art facility houses a diverse range of equipment: from intricate milling and lathing to precise water jet cutting and 3D printing, their skilled technicians can bring complex designs to life. Welding and assembly complete the process, ensuring that each structure is built to the highest standards.
Catherine, our Engineering Manager says: ‘Each Offshore Spars rig is customized and built by hand to our exact clients’ needs. With every project being unique, we have built an impressive team of experienced craftsmen and designers who utilize our equipment and manufacturing processes to their highest potential.’
To ensure a flawless finish, Offshore Spars boasts two state-of-the-art paint booths. These climate-controlled environments provide the ideal conditions for applying high-quality coatings that protect carbon fiber masts from UV damage as well as corrosion from salty marine environments. The paint process is a meticulous one, with multiple layers of primer and stages of fairing before the top coat, to achieve a durable and aesthetically pleasing finish.
Offshore Spars' commitment to quality extends beyond the manufacturing process. Their frozen material storage facility maintains temperature-sensitive materials at optimal temperatures, preserving their integrity and ensuring consistent performance. Additionally, the material slitting & clean room provides a controlled environment for precise material handling and preparation, minimizing the risk of contamination.
Behind the scenes, a dedicated team of engineers, technicians, and craftsmen work tirelessly to bring Offshore Spars' vision to life. Their expertise, combined with the latest technology, enables them to deliver creative solutions in the carbon fiber masts for boats industry.
Bob, our General Manager says: ‘With the collaborative environment at Offshore Spars, it allows each team member to have a voice which improves their quality of work and productivity. It is truly amazing to see the passion each team member brings every day.’
As you explore Offshore Spars' facility, it's clear that their commitment to innovation, quality, and customer satisfaction is unwavering. They are not just building structures; they are shaping the future of carbon fiber construction.
To book an appointment with someone from the Offshore Spars team, fill out our form here.
