First, our engineers create some of the world's most innovative designs. Using solid modeling CAD, advanced finite element analysis software and extensive testing, they maximize Roplene's incredible resilience, strength and shock‑absorbing characteristics. The resulting designs are as stylish as they are functional.
Each design that makes the grade is passed onto our tooling department to be transformed into a state‑of‑the‑art, CNC'd, TIG‑welded, all‑metal mold capable of withstanding our 500°F+ molding process. Storage boxes, gunwales, transom, hull, deck cap — everything is molded into a single, seamless piece.
The mold is partially filled with a charge of the powdered Roplene material. The mold is the moved into our state of the art, 500°F oven where it is rotated while the entire oven rocks. As the heat from the oven penetrates the mold, the powdered material starts to melt and stick to the interior surfaces of the mold. The process continues until layer after layer of material is built up and fused into a single, seamless piece. Each second of the process is monitored by advanced sensors and fine tuned along the way by a highly sophisticated computer program.
Once the computer confirms the cooking process is complete and all material is properly distributed, the mold moves to the cooling process. During cooling, the mold is precisely rotated while the computer program continues to monitor the process, controlling cooling rate the entire time and ensuring a consistent, high‑strength boat from bow to stern.
After separating the two halves of the mold and removing the virtually completed boat, we inject high‑density, 20 lbs.‑per‑cubic‑foot foam into the transom and 3 lbs.‑per‑cubic‑foot foam into the sidewalls and interior cavities of the hull and deck, far surpassing the U.S. Coast Guard requirements for both foam quality and volume.
Step six is equally thorough. Production teams align subassemblies using locator points molded in the hull. Each installation is double checked against master patterns and templates. Triumph's CNC router forms decks, hatches and other parts to hair's‑breadth tolerances. Fuel tanks are pressure‑tested twice to ensure airtight integrity. Electrical systems feature corrosion‑resistant, solder‑coated copper wire along with sealed terminals and connectors for trouble‑free service. Every step in the process is documented and inspected again to ensure a lifetime of carefree enjoyment.