In March 2024, Digital Dry Dock began an exciting project with Alchemy Contracting to support the refit of Dorus Mor, a workboat critical to their operations. In this blog we outline the process, including initial scanning to lifting to stability analysis. 

Phase 1: Pre-refit survey

The project began with a 650-mile road trip each way to Oban, Scotland – a journey planned to ensure optimal weather conditions for the survey and to take in the stunning coastal scenery.

On March 20th, we conducted a detailed survey of the Dorus Mor, capturing comprehensive data to facilitate the refit process. This allowed us to create both a colour point cloud 3D representation of the vessel and a digital twin, to help Alchemy Contracting plan the refit effectively, communicate with subcontractors, and liaise with relevant authorities.

Phase 2: Lifting the vessel 

To ensure the safe crane lift of the vessel onto a steel cradle, we estimated the centre of gravity. Using a centreline slice of the point cloud data, we calculated the centre of area to inform critical lifting decisions. This step minimised risk and streamlined planning for the cradle setup.

Phase 3: Stability analysis 

In April 2024, we created a detailed mesh surface model of Dorus Mor, suitable for use with Max Surf naval architecture software. This model was integral for performing stability analysis, ensuring the vessel met all regulatory and operational requirements post-refit. This in turn enabled us to update the stability model for the vessel.

Phase 4: Crane feasibility study

Another major task was to assess the feasibility of relocating the onboard crane. We conducted a detailed study to determine if the proposed location was structurally sound and established safe loading limits. This analysis provided the client with confidence in their refit plans.

 Phase 5: Full CAD surface model 

The final milestone was completed in January 2025, when we delivered a full CAD surface model of the vessel. This included: 

• A high-precision 3D surface model for use in refit planning; 
• 2D sections and elevations extracted from the CAD model to support design and construction;
• General Arrangement Plan to provide an overview of the vessel’s layout, guiding the refit process.

Final result 

Through advanced digital techniques and collaboration we supported Alchemy Contracting in delivering a safe and efficient refit for Dorus Mor. From a detailed survey to crane feasibility and stability analysis, every step was designed to meet the highest standards of accuracy, safety and functionality.

For inquiries about similar projects, contact us at Digital Dry Dock. 

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Why ornamental half models?

Originally used by shipyards to communicate design features to vessel owners before they were made, half hull models are often found mounted on a board. They are exact scale replicas of one half of the ship’s hull, without the rigging or other fixtures. Whilst today boats are designed using computer modelling, half hull models are often still built as nautical art after the boat is completed. They may also be used in competitive sailing as trophies, or as gifts for sponsors or commercial owners. For some, half hull models are also seen as collector items, with some fetching extremely high prices on the market.

Digital Solutions for Displaying Naval Architecture

Digital Dry Dock can quickly produce a digital half hull model from any vessel’s point cloud or 3D scan data. Depending on the purpose of the model there is the option to either CNC mill or 3D print them from a range of materials.

When requested for decorative purposes, we can CNC mill the designs from wood, to provide an elegant, solid and quality replica. There are a range of finishes which can be provided, or the finish can be left ‘raw’ for finishing by the boat owner if required.

In the instances where half hull models are still used for design concepts, there is the option to 3D print the hulls at a significantly lesser cost. This can help with visualising design features, particularly when the appearance of the vessel is priority, without spending more than is necessary.

Alternatively, we can supply just the digital half hull model should the customer want to find their own route to manufacture or where digital visualisation is enough.

Results

Regardless of finish, all half hull models are exceptionally accurate to-scale replicas of vessels, which can be provided with a quick turnaround.  Our scanning technology makes creating a 3D half model a relatively quick and easy process, particularly when compared with traditional methods of working from manual measurements.

CNC Milling of Wood laminate method.

If you’re interested in a half model design concept or replica of your vessel, get in touch at info@digitaldrydock.co.uk to see how we can create one for you.

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Isles of Scilly Passenger Ferries

The Isles of Scilly is a remote archipelago, 28 miles from the Cornish mainland. With over 140 islands, the smallest no larger than a rock and the largest no bigger than three by two miles, the inter-island passenger ferries are an essential part of life in this remote corner of the United Kingdom. The ferries run services between the five inhabited islands – St Mary’s, Tresco, St Martin’s, Bryher and St Agnes. They also run routes to Samson, the largest of the uninhabited islands.

Earlier this year, five of the inter-island passenger ferries had their draught mark positions in question by the surveying authorities – the Maritime and Coastguard Agency (MCA) and a naval architect. Draught marks are used by the master to ensure that the vessel is not overloaded, as according to its stability book datums, before leaving port.

Digital Solutions for Complying with Naval Architectural Standards

 Being in a remote location, traditional methods of checking draught mark positions require boat owners in the Scillies to spend multiple days, or even weeks, travelling to mainland boatyards and having work carried out. To save the time, hassle and costs of doing so in addition to their annual haul out and maintenance period on the mainland, the ferry owners asked Digital Dry Dock if we could complete the work alongside the routine maintenance work.

By conducting a 3D laser scan survey of the vessels, we were able to create an accurate ‘as-built’ digital twin for each vessel, working around other contractors who were conducting GRP modifications, engineering works, antifouling and painting work. After scanning, we applied the stability book datums to the models, to determine where the draught marks should be compared to where they had been marked so far on the hull.

The next step was to produce a 2D CAD drawing which could be used to show the correct position, size and spacing of the marks. This drawing included measurements taken from the digital twin, which allowed us to position them with far greater accuracy than traditional methods calculated by hand, as well as saving ferry owners time and money by limiting their time on the dry dock.

The Result

With our method approved by the MCA we were able to CNC laser cut new marks and install them on the beach in St Mary’s, saving the vessel owners an additional trip to the mainland. Our methods also made it possible to avoid the arduous, time-intensive and costly process of manually levelling the vessels to ‘real world level’ before positioning the marks. By using 3-axis laser levels with a survey grade elevating tripod to lay them out, we were able to position the marks within an hour. These positions were then verified by the MCA before we installed them on the GRP hulls with a permanent mastic adhesive.

As a result, the naval architect and MCA are now satisfied that all five ferries’ draught marks comply with naval architectural standards.

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At Digital Dry Dock, we combine naval architecture with the latest digital technologies to significantly reduce project costs, schedules and the time vessels spend in dry dock. Often, our technology removes the need for time spent in dry dock altogether. In our latest blog series, Digital Solutions for Naval Architecture, we share some case studies with you to demonstrate how we gather data and how this helps our customers to build things in a smarter, faster way. In these three recent examples, we were able to support maritime businesses to deliver CAD support for new passenger ferries, to ensure compliance with naval architectural standards and to create 3D half models for use in design and decoration.

St Michael’s Mount Passenger Ferries

St Michael’s Mount is a tidal island in Mount’s Bay, Cornwall. Accessible via a set of iconic granite steps at low tide, as the tide rises the historic castle and its surrounding gardens can be accessed only via the passenger ferries. According to St Aubyn Estates, the Mount welcomes as many as 350,000 visitors per year. There are nine passenger ferries which service the island, operating between the end of March and the end of October.

The Mount had two new ferries built, ready for the start of the 2018 season. Happy with the outcome, they decided to produce four more identical boats. However, they wanted to switch boat builders and didn’t have any CAD drawings to work from, as the originals were custom small-scale builds.

Digital Solutions for Naval Architecture – CAD

We were approached by M2ED & St Aubyn Estates to see if we could help them replicate the new passenger ferries. Soon afterwards, we deployed to Mount’s Bay and scanned one of the two existing vessels to gather data for a complete set of CAD construction drawings and models. The combined interior and exterior scan took one day, including confined compartments such as the bilges and lockers. Digital Dry Dock was also able to scan the moulds, all of which made it possible to supply a set of detailed images and full-scale templates so the new builder could quickly understand the construction process.

The Result

Within one month of scanning, M2ED & St Aubyn Estates were supplied with the CAD package of 2D drawings and 3D models they needed to create exact replicates of their new ferries. The Mount then used the digital drawings & models for the build tendering process where, after having an opportunity to review the CAD work, local boat builders were asked to bid for the work. Once a builder was selected, Digital Dry Dock was available on request to supply any additional information needed. For example, to extract measurements from our scan results if there was something the builders were unable to get from the drawings.

St Aubyn Estate is the proud owner of two additional new passenger ferries, with the remaining two set to be ready to service the island in time for the end of this year.

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Why is reverse engineering necessary?

 Before we start, it’s worth considering some of the reasons why reverse engineering may be necessary for boat builders, boat owners and other marine stakeholders. Here are some of the main reasons, all of which our digital laser scanning solutions can help you with:

• Existing designs may be drawn on paper or developed without drawings
• Existing CAD designs may not be accurate
• Existing CAD designs may be missing or lost
• Production moulds may have been bought from original creators without the CAD designs

 Click here to learn more about Digital Dry Dock’s services, and how we can reverse engineer CAD models for your vessel.

Point Cloud over Mesh Model

The Multimarine Project

Redesigning vessels to keep up with the latest trends and technologies is crucial to maintaining Multimarine’s reputation as ‘unique innovative and highly personalised boatbuilders’. On this occasion, our role was to create CAD models of the hull and deck structures of some of their vessels and full CAD models of some of their small production catamarans. These CAD models will now be used to design new variants of the existing craft, so that they can customise and fine tune the original designs.

How was the work carried out?

Ollie visited Multimarine and scanned a mixture of GRP moulds and GRP boats within the same day. He was able to use laser scanners to create digital twins of the vessels and to capture their hull and deck forms. From the point of scanning, the data was processed within two days to create 3D CAD models with an accuracy of less than 3 millimetres.

 What was the alternative to laser scanning?

 Without laser scanning, a skilled draughtsman would have needed to take painstaking manual point measurements along slices through the hull shape at known intervals. They would then ‘loft’ lines and surfaces through them to redraw a very similar representation of the subject. This would take days rather than hours and be far less accurate, regardless of the skill of the draughtsman.

How will Multimarine use these CAD drawings?

Once they received the 2D and 3D CAD drawings, Multimarine were able to design modifications on top of them, to improve the existing vessel design. This means they can create new production moulds, bespoke parts or new customisations with high accuracy and precision.

What did Multimarine have to say?

 “I’d like to thank again the team at Digital Dry Dock for the amazing scanning work we received the other week. We have been looking to digitise a variety of older vessels in our yard that did not have up to date CAD files. 

Ollie Graffy assisted us using scanning gear and point cloud mapping software, providing us with accurate hull and deck models. These models… will allow us to further hull development for resistance and stability assessments, while providing us a basis to develop new interior and deck configurations.”

– Luca, Multimarine Designer

To learn more about how we can help you with reverse engineering CAD designs and much more visit our website. Or get in touch at info@digitaldrydock.co.uk.

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MV Investigator and Geoquip Marine

A geotechnical drillship, the MV Investigator is a 200 foot, 4-point moored vessel which carries out offshore geotechnical site investigations in shallow waters. The fleet works across the globe to carry out drilling operations and support the work of multiple industries, including offshore renewables, infrastructure, scientific research, mineral exploration and oil & gas.

A longitudinal section through the colourised point cloud of MV Investigator

Scanning a drilling vessel

To carry out its work across a range of areas, MV Investigator’s aft working deck must be occasionally reconfigured to fit the nature of her work. Geoquip Marine requested Digital Dry Dock’s services to provide them with a 3D CAD model of the working deck and drill derrick, to make the deck and machinery repurposing process easier.

Digital Dry Dock scanned MV Investigator at Portland Harbour, UK. Over the course of a day, two surveyors were able to record 251 scan locations covering the whole of the weather deck and all deck machinery. With the remaining time Digital Dry Dock was able to scan the machinery spaces including the steering room, storage space, moon pool, engine room and engine control room.

Within 3 days of the survey, Digital Dry Dock registered and linked together a total of 551 links to create a final point cloud, including 251 panoramic images of each scanning location. Geoquip are now able to review the condition of the ship on the day of the survey and to refer to images for point-to-point measurements. A full deck model (including the drill derrick) will be delivered within three weeks of scanning.

Why 3D digital scanning?

Traditionally, the measurement of vessels is done manually and requires a naval architect or engineer to spend several days on board. Opting for Digital Dry Dock’s 3D laser scanning services streamlined the measuring process whilst also causing less disruption to MV Investigator’s normal working activity.

Investigator’s drilling derrick surveyed in 360-degree HDR imagery and intensity point cloud data

Accurate and accessible data

All measurements are accurate to within three millimetres, giving Geoquip reliable data which can be used for refits, remodels and any other future modifications. Data is supplied in any CAD format, includes 360 photography and can be easily accessed and shared with engineers, architects, colleagues and customers anywhere in the world.

A basic data processing workflow with quality assessment.

Making future refits easier

Solidworks models can now be used to design modifications and improvements. Because data is accessed remotely, accurate measurements can be viewed by anyone working on future vessel modifications and refits. This will streamline the planning process and enable modifications to be pre-manufactured whilst the vessel is still in operation.

Less asset downtime

Because the scanning process can be carried out when the vessel is in operation and modifications can be premade from a location other to the vessel, there is minimum disruption to MV Investigator’s normal working activity and less time in dry dock. Minimising asset downtime has significant time and cost savings.

What this means for Geoquip Marine

Moving forward, Geoquip Marine will continue to carry out safe and effective drilling operations across the globe. The investment in 3D digital twins of MV Investigator is a demonstration of their dedication to optimising their vessels and operations so that they can deliver the best possible service to customers.

To learn more about their services, visit www.geoquip-marine.com.

Investigator’s forward deck in colourised point cloud data with scan locations.

All scan locations also have 360-degree dimensionally accurate images (shown above). Leica TruView software has easy to use tools to measure areas, angles and distances.

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Twelve months later and we’re happy to say that the evidence strongly suggests that this was the case. In that time, we’ve worked with dozens of clients across the UK and Europe, created 75 digital twins, and supported numerous vessels with refits, drawings and fit for purpose data.

In fact, at a time where it’s been more difficult than ever to move vessels and to bring teams together to work on naval projects, we feel that 3D laser scanning has proved invaluable. Being able to record, process and present the required data even when vessels are thousands of miles away from the teams working on them, has enabled many of the projects we’ve been a part of to not only continue, but also to make time and cost savings which were previously unseen in the industry.

That being said, we’ve learnt a lot in the last year too. This has enabled us to develop our products, procedures and business operations, whilst also becoming members of the Royal Institution of Naval Architects (RINA) and beginning to conduct professional training. We’ve also moved into our own offices in Mylor, where we have been able to set up our own hardware and software utility.

We’d like to use this as an opportunity to say a huge thanks to everyone who has been a part of the journey so far. It’s been a privilege to work with a wide variety of fantastic clients on a mixture of military, commercial and private sector vessels. We’re excited for the future and feel more passionate and driven than ever about what we can bring to the future of naval architecture.

If you’d like to learn more about what we do at Digital Dry Dock and how we’re trying to revolutionise naval architecture with our advanced surveying techniques, then please check out the video below.

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Location	Lymington, UK
Date	June 2021
Activity/ Tech used etc… (bullet points)	3D Laser scanning of 20 meter classic racing yacht for North Sails UK.Laser scan survey conducted in line with ORC Hull Scanning standard… https://www.orc.org/rules/Hull%20scanning%20measurement%20guide.pdfScanned deck and interior to define mast bury and chainplate/rig geometry.Survey complete in 1 day with minimal disruption to other refit works underway at the time.Point cloud cleaned and used to generate accurate mesh model of the hull.https://sketchfab.com/models/32b52e8edac2478d9e5ceccb4349b821/embedCrufab by DigitalDD on SketchfabCAD Surfaces model produced from mesh model.Digital Dry Dock’s Orca3D naval architecture software used to establish hydrostatic and  stability data.Hull symmetry analysis provided.
Outcome/ end benefits to client	The vessels original drawings could not be found.Provided accurate displacement.Provided accurate CAD surface models of the hull and appendages.North Sails Design Services Consultancy used the models in their Hydro CFD software to conduct a Performance Prediction Study.The study was used to determine a new rig plan/sail plan and ballast configuration.Data processing delivered within 1 week after the survey was conducted.All data stored securely ready to assist in future refits and modifications.

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These projects are excellent examples of how versatile 3D digital scanning can be. The two vessels we worked on – M.V Conway Castle and Lantic Bay – were in very different locations geographically, one of which required the completion of work within a short time frame.

As naval architects, it’s projects like these which inspired the creation of Digital Dry Dock. We understand that being able to complete work in short time frames without compromising on precision is crucial to effective vessel construction and maintenance operations.

We were able to deploy at short notice and work around normal shipyard operations, meaning that site activities were able to continue whilst we were on site surveying. As a result, both project outcomes included huge time and cost savings for the client, compared to traditional dry dock measuring techniques.

The case studies below provide more information on each of the projects.

Case Study: M.V. Conway Castle

The vessel: The MV Conway Castle is the largest passenger vessel on the River Severn (104 ft), licensed for up to 195 passengers with 2 exterior and 2 interior decks. She was based in Arctic Road Dry Dock in the Isle of Wight earlier this year, when work commenced.

 The job: To provide dimensional data used to facilitate the rapid conversion of the vessel from a passenger river cruise vessel to a high end floating restaurant. Our purpose was to scan her hull and superstructure to produce data used to calculate her stability characteristics. This was to allow the design team to quickly draw up and manage her steelwork modifications, enabling the new superstructure to be built off-site and to the correct size.

The challenges: The project needed to be completed within a short time frame (as soon as possible), with work being split between two different yards. This was necessary to enable the removal of the existing superstructure and the construction of a new one to be carried out simultaneously.

What we did: MV Conway Castle was scanned twice. The first survey of the deck and interior took place in Sharpness (December 2020) whilst the vessel was afloat. Drawings were provided within two weeks, over the Christmas period. The second survey of the hull and superstructure took place in the Isle of Wight dry dock, with drawings provided two days afterwards. Using Digital Dry Dock’s point cloud data, a new superstructure was built in aluminium.

 The outcome: The data collected made it possible to complete stability simulation analysis within a short time-frame before works commenced. Without 3D laser scan data the client would not have been able to build the new superstructure and modifications in a different location to the vessel.

Case Study: Lantic Bay

The vessel: Lantic Bay is a 95ft dredger based in Polruan on the Fowey Estuary. She is owned by C. Toms and Son Ltd and is known as one of the most successful builds of Brazen Island shipyard. Lantic Bay has undergone multiple previous modifications to enable her to move vast quantities of dredged material from Fowey Harbour.

 The job: Working with the shipyard, Fowey Harbour Commissioners and a naval architect to oversee Lantic Bay’s refit and the installation of a new digger mounted on her forward deck. Our role was to scan the hull to provide the basis for updating her stability book and to check if the deck structure was strong enough to support the new digger.

 The challenges: Whilst a relatively straightforward scan, we aimed to complete work within one day whilst navigating the underneath of the vessel, narrow hatchways and ladders.

 What we did: After completing the necessary health and safety checks, we scanned the vessel upon the same slipway she was originally built. 130 scans of the hull were completed within 7 hours using a laser scanner, to produce a digital twin. All scans were carried out without causing any disruption to the yard team or the yard’s workflow. The yard manager was able to see the data on an ipad before we left the site.

 The outcome: Data was available to the client (M2ED Ltd.) within three days of the scanning survey being completed. The data provided a model of the hull and deck of Lantic Bay in a format which could be used to assess the vessel’s stability characteristics and update her stability book. This made it possible to determine how much load she can safely carry, influencing the design of the new digger. Without 3D laser scanning, the client would have been required to spend several days taking manual measurements to produce an estimate of the hull shape, or to rely on original (and potentially outdated) stability data. The overall result was a significant time and cost saving, plus improved accuracy and a better stability book, making for a safer vessel.

 Testimonial: “What they can achieve in a short time period is not only far more accurate than existing techniques, the cost savings are also very significant” – Miles Pinchin, Naval Architect, M2ED Ltd.

Follow this link to watch a ‘Fly-Thru’ movie of the Conway Castle and Lantic Bay data sets…

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We are proud to announce that our co-founders Ollie Graffy and Benjamin Barton are now recognised members of the Royal Institute of Naval Architects (RINA).

An internationally renowned professional institution, RINA was founded in 1860 in London to ‘advance the science of ship design’. Its members are recognised as demonstrating the achievement of the highest standards of professional competence in naval architecture.

Both Ollie and Benjamin have been awarded membership in their own right, with each of them being deemed as meeting the required standards.

Ollie Graffy

Ollie was first noticed by RINA whilst studying Engineering Marine Technology at the University of Plymouth. In 2016, his final year project was awarded first prize in the RINA – BAE Systems Student Naval Architect Award.

Last year, he presented the Digital Dry Dock laser scanning technology to RINA and the Institute of Marine Engineering, Science and Technology (IMarEST). Ollie has since been made a member of RINA and received endorsement from IMarEST.

Benjamin Barton 

Ben has recently finished studying Naval Architecture at The Lloyd’s Maritime Academy. He has extensive experience in major refits and dry dock periods, plus ten years experience in skippering sail and motor yachts up to 30 metres in length.

Ben has worked as Chief Mate on two large motor yachts and completed a number of challenging passages to remote corners of the world.

He received his membership to RINA at the beginning of 2021.

Moving forwards, Ollie and Ben are looking forward to learning from and contributing towards RINA, whilst continuing to improve efficiency throughout the build, refit and lifetime of vessels using 3D laser scanning technology.

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