{"id":19784,"date":"2025-08-13T09:14:30","date_gmt":"2025-08-13T15:14:30","guid":{"rendered":"https:\/\/www.ulprospector.com\/knowledge\/?p=19784"},"modified":"2025-09-24T09:15:30","modified_gmt":"2025-09-24T15:15:30","slug":"pe-lightweight-composites-help-vessev-launch-its-all-electric-hydrofoil-boats","status":"publish","type":"post","link":"https:\/\/ulprospector.ul.com\/19784\/pe-lightweight-composites-help-vessev-launch-its-all-electric-hydrofoil-boats\/","title":{"rendered":"Lightweight Composites Help Vessev Launch its All-Electric Hydrofoil Boats"},"content":{"rendered":"
\"\"
New Zealand ferry operator launched a commercial service using the 10-passenger VS\u20139 earlier this year. (All photos courtesy of Vessev)<\/figcaption><\/figure>\n

Vessev, an Auckland, New Zealand-based company, is seeking to redefine sustainable marine transportation by leveraging lightweight composite technology to create its new, all-electric hydrofoiling boats. The first model \u2013\u2013 the VS\u20139 \u2013\u2013 is a 9-meter-long passenger vehicle that went into commercial service in Auckland in January.<\/p>\n

Now it is actively eyeing the huge American market with plans to manufacture its keels there after appointing marine technology veteran Josh Trout earlier this year as its Rhode Island-based director of Vessev USA.<\/p>\n

Fullers360, New Zealand\u2019s largest ferry transport and tourism operator, on Jan. 30 began using the boat to carry passengers on tourism trips across Auckland\u2019s waterways. This marked the first time ever that a certified electric hydrofoiling vessel has entered the fleet of an operator for commercial services.<\/p>\n

\"\"
The all-electric hydrofoil boat can reach speeds of 29 mph, with a single-charge range of 57 miles.<\/figcaption><\/figure>\n

The VS\u20139 can transport up to 10 passengers and provide an experience that Vessev says \u201cis more like flying than sailing.\u201d Its highly efficient, state-of-the-art hydrofoiling technology borrows heavily from proven racing technology. (New Zealand, after all, introduced modern hydrofoiling to the world in the 2013 America\u2019s Cup.)<\/p>\n

These vehicles, designed for commercial operations and tourism, represent a quieter, more efficient, and sustainable option for sea travel.<\/p>\n

 <\/p>\n

Carbon fiber and Epoxy Composites<\/strong><\/p>\n

\"\"
COO Garry Jolliffe began his career with materials supplier Gurit and has now been with Vessev for four years.<\/figcaption><\/figure>\n

Garry Jolliffe, the firm\u2019s chief operating officer, notes that the VS-9 is built primarily from carbon fiber\/sandwich\/epoxy laminates fabricated from resin infusion. Jolliffe previously served as principal engineer at Auckland-based VMG Composites Ltd.<\/p>\n

Vessev makes the skins from a mixture of lightweight woven and non-crimped materials in the 200-800 gsm range.\u00a0And they source\u00a0 the reinforcements from a number of global manufacturers\u00a0via local distributors in New Zealand. The firm uses Gurit M-foam\u00a0<\/a>(a\u00a0marine-grade styrene-acrylonitrile polymer) from Switzerland\u2019s Gurit Holding AG as the sandwich core material.<\/p>\n

It applies the material in various thicknesses (10-40 mm) and densities (80-130 kg\/m3<\/sup>).<\/p>\n

New Zealand epoxy producer Adhesive Technologies Ltd.\u00a0formulates and supplies its ADR range<\/a> of resins to Vessev. Jolliffe says this is a system formulated specifically\u00a0for resin infusion with a low viscosity\u00a0and long pot life.<\/p>\n

\u201cThe combination of the materials allows\u00a0individual\u00a0laminates to be optimized for strength, stiffness and toughness,\u201d he said.\u00a0Vessev adds additional reinforcement for global structural\u00a0loads that allow the platform to be supported on the three foils struts.\u00a0They supplement that with local support via monolithic reinforcement zones at the connection points of the platform and foil cases.<\/p>\n

\"\"
Garry Jolliffe (center) assists two colleagues with composite construction in the factory in Auckland.<\/figcaption><\/figure>\n

When foil borne, the structure has a maximum displacement of 4,000 kg for the VS\u20139. \u201cIt needed to be lightweight, yet robust enough for commercial service,\u201d Jolliffe noted.\u00a0Vessev\u2019s research indicated that a carbon fiber\/sandwich construction was the only viable method to provide a payload of suitable capacity for the VS-9 when foiling.<\/p>\n

The company \u2013\u2013 which was reborn as Vessev in April 2024 after previous iterations (dating back to 2018) as Freight Fish and then Seachange \u2013\u2013 constructs the VS\u20139 using a combination of tooling options.\u00a0It molds the more complex parts (using a mixture of male and female tooling) with the larger single curvature parts. It fabricates those latter parts on a laminating\u00a0table with local tools for features aligned on the table during construction to provide details where required.<\/p>\n

For maximum durability, the VS\u20139\u2019s foils can fully retract, enabling the vessel to operate in shallow water while also protecting the foils so the vessel can be transported on a trailer.<\/p>\n

\n

Discover Material Selection with Prospector Premium, learn more here<\/a>!<\/h3>\n
\n

As regards engineering\u00a0challenges for the VS-9, Jolliffe noted that outside of the constant\u00a0focus on weight \u2013\u2013 which is the biggest driver for vessel efficiency \u2013\u2013 packaging is definitely\u00a0the next biggest challenge.\u00a0An example is providing enough space for service runs (which are different for an electric vessel, and more so for electric hydrofoiling vessel than a traditional vessel) throughout the composite structure. At the same time, it\u2019s vital to maintain watertight boundaries and commercially required fire boundaries. This poised a significant challenge that Vessev\u2019s experts had to\u00a0 overcome.<\/p>\n

In-house Manufacturing <\/strong><\/p>\n

\"\"
Since January, Josh Trout has headed up Vessev USA, based in Rhode Island.<\/figcaption><\/figure>\n

\u201cWe build everything in-house,\u201d Trout said in a July 31 phone interview from New Zealand. Vessev has about 50 employees, including experienced boat builders, designers and engineers with diverse backgrounds.<\/p>\n

“With two VS\u20139s in service, providing a wealth of user feedback, Vessev now is gearing up to move from small-batch production to a more scalable process, he said. This will enhance production efficiencies and lower costs.<\/p>\n

Trout explained that Vessev can build its boats in New Zealand and work with various national regulatory bodies worldwide to meet the local requirements \u2013\u2013 in 98 percent of the markets. The exception is the United States. A century-old law \u2013\u2013 called the Merchant Marine Act of 1920, also known as the\u00a0Jones Act<\/a> \u2013\u2013\u00a0is a U.S. federal law that regulates maritime commerce in the United States. It stipulates that any marine vessel that moves cargo or people for money must<\/em> have its keel made in the U.S.<\/p>\n

With the U.S. being the biggest global boat market by far (bigger than all of Europe combined), Vessev is committed to manufacturing its product in the United States for compliance reasons. \u00a0Trout says he now has identified four U.S.-based boat builders who he is confident have the ability to manufacture Vessev\u2019s products to the same quality as it does in New Zealand.<\/p>\n

He is not ready to identify those firms yet, but notes they are on both coasts and that the company hopes to begin State-side production by the first quarter of 2026. It can continue to build their motors and hydrofoils in New Zealand, but the keels must be laid in the U.S.<\/p>\n

\u201cWe have sold boats in the U.S. already, and we know they must be Jones Act-compliant.\u201d He says Vessev already has also sold boats in Europe and in the pan-Asia region.<\/p>\n

All-electric & Highly Efficient <\/strong><\/p>\n

\"\"
The first electrical control boxes get installed into the VS\u20139 following completion of the composite structure.<\/figcaption><\/figure>\n

\u201cThere\u2019s a huge push around the world for electric vessels,\u201d Trout said. Hydrofoils allow the current level of infrastructure in the marine space to be effective as a transport medium.<\/p>\n

To use an electric motor to power a conventional boat that displaces water, one needs a really big battery, which is very inefficient. With a big battery, you also need bigger charging, so the boat can charge in a reasonable amount of time.<\/p>\n

A very good infrastructure of charging outlets already exists in the marine industry, Trout noted. But it could take, say, eight hours or more to charge a big battery using a 50-amp outlet. And then the amount of run-time you get out of that is not great.<\/p>\n

\"\"
This shows the boat\u2019s internal structure (longitudinal and structural shelf) installed into the demihull.<\/figcaption><\/figure>\n

In contrast, with a hydrofoil, you\u2019re removing about 90 percent of the drag on the boat when it is up on the foil. It can go faster, while using just a fraction of the energy needed to power other types of boats. And one also can use smaller, lighter batteries, while getting a great range.<\/p>\n

The VS\u20139 has a service speed of 25 knots (29 mph) and a range of 50 nautical miles (57 miles) on one charge.<\/p>\n

Vessev is getting all its tooling prepared for serialized production and Trout predicts that by year\u2019s end they can start building boats to fill the orders they have. Conservatively, by the end of 2026 he says they want to be building one boat a month, with the goal of eventually building a few boats a month.<\/p>\n

The base price for an open-style VS\u20139 is US$576,000, while a fully loaded boat (with a totally enclosed cabin, with heating and air conditioning, higher-end upholstery, seating, lights, stereos, etc.) will carry a higher cost, based on each customer\u2019s operational requirements.<\/p>\n

\u201cIf you\u2019ve ever been on a hydrofoil,\u201d Trout says, \u201cit\u2019s like no other boat on the planet. There\u2019s a \u2018wow\u2019 factor.\u201d In addition to being quiet and sustainable, it\u2019s a fast, smooth ride. “The boat also performs a banked or coordinated turn, in contrast to a traditional vessel that performs a flat turn, which will push you to the outside of that turn.”<\/p>\n

Vessev, meanwhile, is gearing up to help boat enthusiasts and others fill that niche \u2013\u2013 not only with the 9-meter VS\u20139, but potentially with 12- and 18-meter-long platforms, as well.<\/p>\n

 <\/p>\n","protected":false},"excerpt":{"rendered":"

Vessev, an Auckland, New Zealand-based company, is seeking to redefine sustainable marine transportation by leveraging lightweight composite technology to create its new, all-electric hydrofoiling boats. The first model \u2013\u2013 the VS\u20139 \u2013\u2013 is a 9-meter-long passenger vehicle that went into … 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He has broad global experience and for more than 35 years has worked as a journalist, editor-in-chief, publishing executive and key connector of like-minded parties. He has launched successful publications and C-level events on three continents. While with Crain Communications Inc., he oversaw the relaunch of the 100-year-old European Rubber Journal in London and helped to start Urethanes Technology magazine there. \u00a0In 1988 Bob returned to Akron, Ohio, to serve as founding editor of Plastics News, an award-winning, weekly business newspaper. In 2005 he oversaw the editorial launch of the bilingual (Chinese and English) PN China e-newsletter and website. For more than a decade at PN he also held the titles of associate publisher, editorial director and conference director, and most recently served as business development director. A long-time affiliate member of the Industrial Designers Society of America, Bob has organized numerous design-focused events, earned a Personal Recognition Award from IDSA in 2013, and constantly strives to help bridge the gap between the design and manufacturing communities. In 2014 he left Crain and created RC Grace LLC in Akron, Ohio, as a consultancy that aims to help companies to enhance their branding and market presence, find business partners, connect with design resources (here or in Asia), secure funding and advance their growth initiatives. Email Bob or visit his website at www.rcgrace.com to learn more about how he can help you.","sameAs":["http:\/\/ulprospector.com"],"url":"https:\/\/ulprospector.ul.com\/author\/robert-grace\/"}]}},"authors":[{"term_id":1244,"user_id":23,"is_guest":0,"slug":"robert-grace","display_name":"Bob Grace","avatar_url":"https:\/\/ulprospector.ul.com\/media\/2017\/10\/Robert-Grace_avatar_1508791447-96x96.jpg","0":null,"1":"","2":"","3":"","4":"","5":"","6":"","7":"","8":""}],"_links":{"self":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/posts\/19784","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/users\/23"}],"replies":[{"embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/comments?post=19784"}],"version-history":[{"count":2,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/posts\/19784\/revisions"}],"predecessor-version":[{"id":19987,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/posts\/19784\/revisions\/19987"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/media\/19786"}],"wp:attachment":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/media?parent=19784"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/categories?post=19784"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/tags?post=19784"},{"taxonomy":"author","embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/ppma_author?post=19784"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}