From boat design to production

How are these small boats made?

Here is a glimpse into the process of making a mold for Wavewalk’s newest portable skiff, the Series 4 –

The pictures below show the wooden pattern produced from solid wood and hard rubber from the CAD (computer Aided design) file for the product.  This first-generation mold will be used to produce a second generation mold called a sand mold. The mold makers will cast molten aluminum into the sand mold, and produce the actual rotational mold in which molders will pour Polyethylene resin, and produce the Series 4 boats.

The cockpit features slanted sides designed to allow the passengers to paddle this boat effectively with either canoe or kayak paddles. Paddling capability is critical to mobility and high performance in shallow water and weed infested water. This design makes poling easier as well as more effective.
The stand up casting platform is supported by integrated structural beams that look like slots when viewed from the top.
Front view that shows the S4 two hulls, which make it a full catamaran.
The stand up casting platform at the front – a typical skiff feature. This platform is particularly appreciated in flats fishing, by fly anglers and other fishers who practice sight fishing.
Rear view with the integrated transom motor mount.
Side view of this ultralight portable skiff.
Bottom view of the pattern for this boat.

More information on the Wavewalk Series 4 »