How MAKAI Hulls Are Made

At MAKAI Power Catamarans, we take no shortcuts and use premium materials throughout the construction process. No shortcuts means carefully laying the best materials for the job, and then conducting a vacuum resin infusion process.

Our goal at MAKAI is to build the best boat, and for us that means the strongest result, and a finish you could eat off. This is the culmination of revolutionary design, thorough engineering, and cutting edge technology, executed with boatbuilding craftsmanship.

Following previous posts on choosing the best propulsion and best engines for your MAKAI, here we have a closer look at our vacuum infusion process and a description of the materials used.

The MAKAI M37 Hulls with gelcoat, tie layer, fibreglass of many types, and prepared for infusion


Our hulls are foam cored to achieve light weight, with maximum strength. The foam used is Divinycell, and the glass used is a combination of triaxial and quadraxial – in summary, the most expensive materials on the market today…

A cross-section of a completed M37 bulkhead: our bulkhead materials are made from immensely thick and rigid, high-quality DIAB foam. Reassuring strength in a boat that can do 40+ knots.


Vacuum infusion allows for thorough soak-through of resin throughout the materials, while ensuring the lowest possible weight by removing any excess. Careful calculation is also required – the exact correct amount of resin should be consumed in the boat. And for us, that’s exactly what happened.

In preparation for vacuum infusion, flow-mat is used throughout the boat to ensure the best spread of resin. Not every boatbuilder does this.

Once every layer is properly stacked and placed and covered with flow-mat the hull will then be covered with a single strong air-tight plastic cover.

The laminates then are covered with a special bag material, which is then sealed to the mould.
Once placed, the cover is vacuum sealed and checked for leaks with digital metres

20 resin tubes were used to supply the resin during infusion, and the process was closely supervised and monitored to check the resin flow ran as predicted as it was pulled through by the vacuum.

The final process was nearly odourless, and used exactly the amount of resin predicted. .

Finally, with the material fully soaked the process was completed. This was a successful resin infusion of a power catamaran.

Now filled with resin, the process is complete – a successful resin infusion