Invincible Boats Current Employment

After my internship at Eurocompositi and attaining my new skills with resin infusion, I had joined the Product Development and Engineering team at Invincible Boat Company at the beginning of 2024. Within this role as the Advanced Product Engineer, I was initially sent to the Merida, Mexico manufacturing facility for 5 months where I worked on the process transition from hand layup fabrication to resin infusion all while training a new group of Naval Engineers the materials and processing of composite boats. The education of Naval Engineers from Mexico is one that is focused mostly on the materials that are readily available to the country which is primarily limited to aluminum and steel ships. The unique opportunity within the country brings in good and experienced candidates for the roles such as my immediate coworker at the time, Juan Cortes, who worked in the past for the Mexican Navy, building aluminum interceptor boats. With the help from Juan Cortes and Joel Casteneda, we had successfully transitioned the production of all of the large parts to resin infusion all whilst battling learning curves and peak environmental temperatures reaching upwards of 110°F. During the transition, we did not have a production failure leading to scrapping of the part which I find to be a monumental achievement given the difficulty of the project. After this transition, I can positively say that the boats coming from the Mexico Manufacturing facility are the strongest and the best quality that Invincible Boat Company has ever had.

My specific duties at the time was to develop and verify infusion manifold drawings, perfect the infusion strategy, implement and revise fiberglass kits, modify production tooling and jigs to be infusion capable, audit the installation of structural members, and implement new product construction into the manufacturing facility including the 33C, 46C, and 43M. By the time I had arrived back into the United States, I had felt honored to see the last hand laid boats go down the assembly line and to know that I had been integral with improving the quality of the product to the greatest benefit to the end client and their safety at sea.

36C Product Development and Integration

With the development of the 36C, a new hull was developed, the deck liner and ring deck was modified. Besides the updates of the hull form to make the boat a drier and a more efficient ride, the structure and construction of the hull was the biggest update to the model. My first deliverable in the project was to develop an infusion manifold to infuse the stringer grid and the bulkheads with the hull paneling. The other set of deliverables was to produce and revise drawings for bulkhead and structure installation, fishbox locations and installation on the liner, and the new general arrangement of the boat to increase the cockpit space in the aft section of the boat. The boat was released at the Miami Boat Show in 2025 and had been a great redesign for the previous 35C.

46C Pilothouse Projects

After my work with the 36C, Invincible had sold three 46C Pilothouse boats within the same year, and they were produced consecutively to each other. This was the most Pilothouse boats that the company had built within a single year, and it yielded a unique opportunity to revise the build process of the boat and to fine tune the quality of the assembly with production builds. This gave me the chance to revise lamination schedules, assembly, and new processes to the builds of these boats.

The first project was to update and add more dimensional control to the build to ensure that the FWD and AFT sections of the pilothouse were aligned during assembly. The following pictures show the process and the results from this control and review of the dimensions.

46C Pilothouse Custom Options

One of the builds for the pilothouse was requested to take Shox Seat Pedestals and an extended aft settee. This was the first time that Invincible had performed this combination, and my tasks were to implement these two custom options for the boat, give feedback to our vendors, drive rework decision making, and further floor support given existing drawings and installation procedures.

38C Dual Row Option

One of my other projects for the company was to develop a new seating option for the refreshed 38C. The new option is to add Dual Row Seating to the boat. This was achieved without any additional tooling investment. The deliverables included a feasibility study between the associated parts, hardtop piping, and lamination schedules. At the end of the project, I had performed a new lamination schedule drawing for the deck liner, a drawing for the hardtop pad landings, new laser cut drawings for the windshield metalwork, and a 3D model for the hardtop piping to ensure the feasibility of the project. The implementation of this option is start in August, 2025.

Above Deck Seakeeper Option Redesign

The engineering department, after some time of installing Above Deck Seakeepers, had decided to revise the design of the option. Previously, the Seakeeper bracket itself was made as a fiberglass part from a mold that was bonded and bolted to the deck with additional reinforcements in the deck liner part. The fiberglass part itself was difficult to fabricate with a high scrap rate which made it difficult to reliably support production with this option. The decision by the engineering department was to design and develop a new deck bracket using 3/8" aluminum that was wider and spanned the width of the stringers for it to be bolted directly to the structural members of the boat. The supporting engineers for this project was Jacob Southern, Michael DeLuca, Juan Cortes, and myself. The scope of the project included the design of the Seakeeper Deck Bracket, and the engineering changes for the feasibility of the installation between multiple models for the 39M, 43M, 38C, 40C, and 46C Invincible models as well as the 39' and 42' Yellowfin monohulls. The engineering department wanted one part that could work between multiple different models between both sister companies.

The engineering changes for the 39M and 43M included mold changes for the stringer molds, new stringer lamination schedules and drawings to add additional reinforcements to the parts, assembly drawings for the location of the Seakeeper Deck Bracket, and a Work Standard to support production. The scope for the catamaran models is an addendum lamination schedule for the deck liner to add additional reinforcements, assembly drawings, and a Work Standard to include the addition of a rig tubes to allow the Seakeeper to be rigged. This option can be found on Peter Miller's 43M which is featured on "Uncharted Waters" on the Discovery Channel. Both Michael DeLuca and myself had been integral within the installation of the gyroscope in Peter's boat.

Below are some pictures showing this option on a 46C