Great boats require great design, great materials and great people. At World Cat, we combine all three to build some of the strongest, safest boats on the water. From the very start, our catamaran hulls and decks are created using sophisticated three-dimensional modeling software to insure structural integrity and precise fit. Each part is computer modeled, even lids and hatches, before our in-house tooling professionals produce the plugs and molds that determine your World Cat’s shape, fit, and finish.

The secret to the World Cat finish is in the molds. So, each mold is polished to a high gloss before the exterior gel coat color is applied. After the gel, a layer of fine mat “skin coat” is laminated into the hull before the structural build the follows. This skin coat forms a barrier between the smooth gel coat surface and the heavier glass behind to assure your World Cat retains its finish and long-lasting value.

After the external layers, bi-directional and tri-directional knitted fiberglass cloth are laminated into the molds by hand with excess resin removed by squeegees to guarantee a correct glass to resin ratio for a stronger, more durable laminate. As an added measure in the hull bottoms, layers are overlapped in water shock areas and a thick layer of 36 ounce woven roving cloth is laminated from chine to chine. To assure proper strength, each part is checked with a Barcol meter to assure hardness and durabilty.

Structural bulkheads and stringers in World Cats are fabricated from high density fiberglass reinforced composite materials that are impervious to water absorption and rot. These structural members form the grid which supports the hull structure. After the stringers and bulkheads are glassed into the hull, strategic cavities are filled with foam for flotation, sound and thermal insulation. Transom systems of high density composite are bonded to the transom and reinforced with aluminum plates in engine-mounting areas. So, your World Cat has an all composite structural system designed to take on the toughest seas for years and backed by our ten-year structural hull warranty.

After the fiberglass parts are pulled from their molds, they enter the trim booth where the outer flanges are trimmed and the parts are cut and drilled using templates in order to accept the component installation in the assembly area. So, when the parts enter the assembly area, they are ready for the installation of components like through-hulls and port lights. This means each component is in the proper place for sure connections and quality control.

In the assembly area, veteran boat builders- many having been with the company for 20 or more years – begin installing the through hulls, rod holders, refrigerators and windshield systems that make your World Cat an enjoyable boat to own and use. Stainless steel hardware is fabricated from 316L grade stainless steel, expensive because of its high nickel and chromium content, but much less susceptible to staining in salt water use. Polyethylene fuel cells are placed into the hulls after being pressure checked. Bilge pumps and other components are installed and then the hulls and decks are ready to be bonded together.

As the deck is lowered into the hull, it is bonded to the tops of the stringer system forming a structural grid like an airplane wing. During the lamination process, a composite ring was secured into the top of the hull. When the deck is lowered onto the hull, stainless steel epoxy-tipped screws are fastened through the deck, hull and into the composite ring. This two-part epoxy heats and chemically bonds the parts to further reinforce the stainless mechanical bond.

Heavy-duty and oversized welded aluminum frames secure fiberglass hardtops and t-tops as the boat takes its final shape. Hardtops and t-tops, fabricated in our lamination area, are vacuum bonded together and feature built-ins like radio boxes, spreader lights and radar mounting areas. Canvas systems are custom fit and installed, then rolled and stored before the World Cat is ready to ship. Engines are installed and tested at the factory too. So, your World Cat is ready for electronics and launching when it arrives at a World Cat dealership

All along the production process, quality procedures and process control mark our efforts to provide the best boats on the water. But perhaps, the greatest World Cat advantage is World Cat people. North Carolina boat builders have a long tradition of quality because of the cruel test of our offshore waters. But, World Cat boat builders combine this dedication with an ability to embrace and utilize new technologies that continuously improve product quality and durability. We don’t rest with antiquated systems and processes, we improve them. While custom yacht builders tout their resin infused hulls, we are putting it to work here at World Cat (check out the resin infusion process below). All composite construction? Check. Silicone vacuum bagging? It makes a lighter, stronger part so we use it.

Great design, materials, processes and people empowered with the latest technology. That’s how it’s built. That makes it World Cat.