Technology - Callegari

TECHNOLOGY

NAUTICAL TRADITION MEETS AEROSPACE TECHNOLOGY

The new Callegari era begins with Aviorec Composites, a company specializing in the aerospace and highly complex industrial sector.

The expertise developed by Aviorec comes from production processes and methodologies applied in fields where structural control, manufacturing precision and performance are essential requirements. Know-how built through collaborations with aerospace and automotive companies such as Avio, Lamborghini and other highly specialized industrial operators.

CALLEGARI DESIGN AND PRODUCTION

This approach is now applied to the design and production of Callegari boats through the use of advanced composite materials, CNC machining, controlled infusion processes, CFD simulations and advanced structural protocols.

Every production phase is developed according to an integrated logic focused on:

WEIGHT CHECK

structural rigidity

mechanical continuity

assembly precision

validation of design parameters

The result is a technological platform designed to ensure structural reliability, dynamic efficiency and industrial repeatability.

A FULLY IN-HOUSE PRODUCTION PROCESS

Each model is built within a short, directly controlled supply chain. A Callegari boat is designed to last over time and accompany owners who demand more.

PROCESSING

CNC MILLING

All components are machined with machining centres; the moulds are produced in-house using aerospace-derived technologies and processes that allow accurate controls and ensure high quality standards.

MATERIALS

COMPOSITE MATERIALS

Composite materials are processed with aerospace technologies: prepregs, autoclaving and infusion at controlled temperature and pressure. This results in lighter, more compact components with long-lasting mechanical performance.

ASSEMBLY

STRUCTURAL BONDING

We use aerospace adhesives to join the structures. It is the same technology that makes aircraft fuselages monolithic. In this way, each part becomes a single body: quieter and more resistant.

MATERIALS

FULL CARBON FRAMES

We manufacture boats entirely in carbon fibre through infusion and controlled post-curing processes. This technology makes it possible to obtain lighter and more efficient structures.

PROCESSES

INTEGRATED PRODUCTION PROCESS

Hull and structural reinforcements are made through an infusion process carried out in a single step, with greater control of the impregnating resin, structural continuity and reduction of the overall weight of the laminates.

STAGING

CONTINUOUS DISPLACEMENT MONITORING

Throughout the assembly process, the vessel is monitored using load cells that constantly check its weight and trim against the design specifications.

TEST

Advanced structural inspections

Each component undergoes non-destructive testing, thermographic analysis, ultrasound and mechanical checks on the composite laminates to ensure maximum structural reliability.

TEST

CFD SIMULATION

The hulls are designed and validated through advanced CFD analysis, used to optimise hydrodynamic efficiency and the behaviour of the vessel in different load configurations and sea conditions.

All components are machined using CNC machining centers; the molds are produced in-house using aerospace-derived technologies and processes that allow accurate controls and ensure high quality standards.

Composite materials are processed with aerospace technologies: pre-pregs, autoclave and infusion at controlled temperature and pressure. This produces lighter, more compact components with long-lasting mechanical performance.

To join the structures, we use aerospace adhesives. It is the same technology that makes aircraft fuselages monolithic. This makes every part a single body: quieter and stronger.

We build boats entirely in carbon fiber through controlled infusion and post-curing processes. This technology makes it possible to obtain lighter, higher-performing structures.

The hull and structural reinforcements are produced through a single-stage infusion process, with greater control of the impregnating resin, structural continuity and reduced overall laminate weight.

Throughout outfitting, the boat is monitored by load cells that constantly verify weight and trim against the design data.

Every component undergoes non-destructive testing, thermographic analysis, ultrasound and mechanical checks on composite laminates to ensure maximum structural reliability.

The hulls are designed and validated through advanced CFD analysis, used to optimize hydrodynamic efficiency and the boat’s behavior across different load configurations and sea conditions.