Manufacturing

LAMINATION

We custom-build pre-preg carbon fibre masts, cured in our aero-space grade autoclave.

• Thin layers of standard or high-modulus unidirectional pre-preg carbon fibre are applied.
• Debulking is performed between every layer to eliminate void contents.
• Spars are laminated at varying orientations, to deliver precise dimensions and strength and stiffness specifications.
• We typically cure at 6-7 bar pressure, but have the capacity to increase to 8 when required.

Hall’s laminating process results in a perfectly smooth, aerodynamic, weight-optimised seamless mast tube.

All carbon components follow the same process and are autoclave cured.
e.g.  mastheads, spreaders/instrument brackets etc.

PRE-ASSEMBLY

All parts are fitted to the mast tube and boom, ensuring each component aligns and fits as designed.

• The highest quality parts and materials are used in all applications.
• Advanced machinery is used to execute designs with precision accuracy.
• Metal parts are machined efficiently by 5 axis milling robots.
• All metallic parts and smaller components receive surface treatment after pre-fit. This includes paint, polish and anodising.
• Non-destructive testing is performed.

FINISHING

To guarantee exquisite aesthetics, the finishing team sands and paints every spar in our pressurised, temperature-controlled booths.

• Dedicated sanding room
• 2x 60m painting rooms
• Quality check after each coat
• A multi layered two component epoxy coating is applied to protect the mast.

We follow ICOMIA Standard 51-18, certification available on request.

FINAL ASSEMBLY

Bringing it all together

• Treated parts and fittings are assembled
• All electric cables are pulled in
• Halyard mousing lines are pulled in
• Mast is pre-rigged as a final factory test
• Locks, lights and sensors are factory tested
• Full setup weighed and centre of gravity determined.

Once signed off, the rig package is expertly packed and secured ready for shipping.