Yacht Portlight Frame

8th Jul 2020

Setting Sail on a New Project

In 2019, Hallam was approached by a leading UK manufacturer of ocean-going yachts, known for serving the global sporting and leisure markets. They were looking for fresh designs and more efficient manufacturing methods for the portlights (windows) in their yacht hulls.

Product Brief

Their goal? To explore whether high-pressure diecasting could be used to produce the portlights as a single, seamless piece—eliminating the need for traditional fabrication. This ambitious shift came with a few key challenges.

Challenges

Switching materials: Moving from fabrication alloys to casting alloys meant selecting and rigorously testing a new material that could handle the job.
Redesigning the portlights: The entire range needed a mechanical overhaul to align with the new manufacturing process.
Testing finishes: We had to ensure that any finishing treatments applied to the casting alloy could stand up to the harsh marine environment.

The new materials and finishes had to be tough—resistant to saltwater corrosion and capable of withstanding years of intense UV exposure, especially in sunny mooring spots like the Caribbean.

Redesigning the portlights was no small feat. They had to fit flush against contoured hulls while also accommodating internal fixings, seals, and anchorage points. Fortunately, Hallam had already developed a portfolio of casting alloys through previous work in roadside and traffic environments—where long-term saltwater resistance is critical.

Conclusion

To validate the new designs, we worked with external testing houses to simulate real-world conditions. This included exposure to saltwater, mechanical stress, and even a decade’s worth of Caribbean sunshine. We used the CIELAB method to assess colour stability after UV exposure.

Today, Hallam manufactures, machines and paints these portlights in a wide variety of sizes and configurations—completely eliminating the need for fabrication.

Combining proper surface keying, and a bespoke 5 stage pre-treatment with a high-quality primer and premium quality powder from AkzoNobel, has helped us deliver exceptional paint durability—even in the most extreme environments.