Fibre-reinforced plastics have transformed small craft and high-speed vessel construction, offering light, strong, corrosion-resistant structures that can be moulded into complex shapes. Using them well requires an understanding of the materials, how they are combined into laminates, how they are processed and how structures are designed against service loads. This course takes in the raw materials, laminate theory, processing methods, boatbuilding practice and structural design of marine composites. Subjects include what FRP and GRP are and where they are used afloat, the fibres, reinforcement fabrics, resins and cores found in marine laminates, the effect of fibre content, ply direction and sandwich build on structural response, hand lay-up, vacuum bagging and infusion, the order of work and quality checks in a boatyard, and the design of composite structures for loads, details and failure modes. Two written assignments, on production and on design review, apply the learning.
Course at a glance: Duration 20 hours · Self-paced online · 8 sections, 31 lessons, a 118-page downloadable course book
What you will learn
- Explain the defining characteristics and marine applications of FRP and GRP composites.
- Differentiate reinforcement fibres, resin systems, reinforcement forms and core materials used in marine laminates.
- Describe how laminate architecture, fibre fraction, ply orientation and sandwich construction affect structural behaviour.
- Explain the basis of classical laminate theory.
- Compare the principal composite processing and moulding methods used in marine construction.
- Outline the boatyard production sequence for composite vessels, including moulding, lamination, core installation and quality control.
- Explain how marine composite structures are engineered against loads, detailing requirements and failure modes.
Inside the course: a high-level summary, section by section.
Composite fundamentals
The course begins with the history and drivers of marine composites. Reliable resins allowed fibres and matrix to be combined into structures lighter, stronger and more easily shaped than many older materials. In FRP, two or more materials work together: the fibres carry strength and stiffness, while the resin holds them in place, passes load between them and shields them from the surroundings. Marine applications range from small boats and yachts to high-speed craft, naval vessels and components on larger ships.
Constituent materials
Fibre types, glass, carbon and aramid, are compared for strength, stiffness, weight and cost. Reinforcement forms, such as chopped strand mat, woven rovings, stitched multiaxial fabrics and unidirectional tapes, determine fibre orientation and how easily the reinforcement drapes over a mould. Resin systems, polyester, vinylester and epoxy, differ in mechanical properties, water resistance, processing and cost. Core materials, foams, balsa and honeycombs, are used to build sandwich structures, and their properties and limitations are discussed.
Laminate behaviour
Fibre fraction strongly influences laminate properties: more fibre generally means higher stiffness and strength, but processing method limits what can be achieved. Ply directionality explains why composites are anisotropic and how plies at different angles are combined to resist loads in multiple directions. Classical laminate theory provides a framework for predicting the stiffness of a laminate from its plies, and the course explains its main ideas and assumptions. Sandwich behaviour shows how separating stiff skins with a lightweight core dramatically increases bending stiffness for little added weight, while introducing new failure modes involving the core and the skin-core bond.
Processing methods
Contact moulding methods, hand lay-up and spray-up, are traditional, flexible and low cost but give lower fibre fractions and more variability. Vacuum bagging and resin infusion use atmospheric pressure to consolidate laminates and draw resin through dry reinforcement, improving fibre fraction, consistency and working conditions. Other manufacturing processes, such as prepregs and closed-mould methods, are introduced with their applications. The choice of process is a balance between laminate quality, consistency, cost and the skills available, and learners are encouraged to think about which process suits which part of a boat rather than treating any single method as universally best.
Boatyard production
The production sequence follows the path from mould to finished structure: mould preparation, gelcoat application, lamination, core installation and build-up of the structure, followed by demoulding and assembly. Quality assurance in production covers material control, environmental conditions, laminate inspection and defect prevention. A production assignment asks learners to plan and justify a production approach. The emphasis on quality reflects a simple reality: many in-service problems with composite boats, such as poor bonding and voids, originate in the yard rather than the design office, and are far easier to prevent than to repair.
Structural design
Structural design practice starts with rules and material selection, explaining how classification and design rules set minimum requirements. Loads in service, slamming, hydrostatic pressure, global bending and local loads, are examined. Detailing, such as joints, bonds, hardware attachments and stiffener terminations, has a major influence on structural performance, and stability of thin skins and panels is considered. Failure modes, including fibre and matrix failure, delamination, core shear and skin wrinkling, are explained, and a design review assignment applies the concepts to a realistic case.
Why composites behave differently from metals
A theme running through the course is that composites must be designed as materials and structures at the same time. Unlike steel or aluminium, whose properties are largely fixed when the plate is ordered, a composite laminate’s properties depend on fibre type, orientation, fibre fraction and processing, all decided by the designer and builder. This flexibility allows material to be placed exactly where it is needed, but it also means that poor processing or detailing can significantly reduce strength. Through-thickness properties are weak compared with in-plane properties, which is why delamination and bond failures are such important design considerations, and why quality control in the boatyard is as important as the design calculations.
From study to practice
The course is structured to mirror how a composite boat actually comes into being: materials are chosen, laminate behaviour is predicted, a process is selected, the hull is built and inspected, and the structure is checked against rules and service loads. Two applied assignments, one on production and one on design review, ask learners to bring these strands together and justify their decisions, which is exactly the kind of reasoning expected of designers, builders and surveyors when they review a real laminate schedule or production plan.
Why this matters in practice
Composites dominate small craft and high-speed vessel construction and are increasingly used in larger structures. Designers, builders and surveyors who understand materials, laminate behaviour, processing and structural design can produce lighter, more reliable vessels and identify problems before they become failures.
Key takeaways
You leave able to explain marine composite fundamentals, select fibres, resins, reinforcements and cores, describe laminate and sandwich behaviour, compare processing methods, outline boatyard production and quality assurance and apply structural design principles to marine composite structures.
How you study
The course is delivered fully online and is self-paced, so you can fit roughly 20 hours of study around professional commitments. Lessons combine clear explanation with examples, diagrams and short interactive checks, and the main sections end with graded quizzes (6 in total) so you can confirm you can apply each method before moving on. A 118-page course book can be downloaded and printed for offline reading and later reference.
Course contents
- Marine Composite Fundamentals: What Makes FRP Composite; History and Drivers; Marine Applications
- Composite Constituents: Fibre Types; Reinforcement Forms; Resin Systems; Core Materials
- Laminate Theory: Fibre Fraction Effects; Ply Directionality; Classical Laminate Theory; Sandwich Behaviour
- Composite Processing: Contact Moulding Methods; Vacuum and Infusion; Other Manufacturing Processes
- Boat Production: From Mould to Laminate; Core Installation and Build; Quality Assurance in Production; Production Assignment
- Structural Design with Composites: Rules and Material Selection; Loads in Service; Detailing and Stability; Failure Modes; Design Review Assignment
- Summary: Key Takeaways
Who this course is for
This course is for engineering graduates, naval architects, boatbuilders, surveyors and production engineers working with composite vessels and marine structures. A basic understanding of structural mechanics is helpful.
Frequently asked questions
How long does Marine Structural Composites & High-Speed Craft take?
The course is designed for about 20 hours of study. It is self-paced and fully online, so you can spread it over a few weeks or complete it more quickly.
What is covered?
The course is organised into 8 sections with 31 lessons, moving from foundations to applied methods, as summarised above.
Is there material to keep after the course?
Yes. A downloadable 118-page course book accompanies the lessons for offline reading and later reference.
How is progress checked?
Each main section closes with a graded quiz (6 in total, with a pass mark of 80%). The quizzes test understanding of the concepts and methods explained in the lessons rather than memorisation, and you can review the relevant lessons before attempting them.
Can I record this study for my own professional development?
Yes. The course notebook includes a self-assessment of the course objectives before and after study, a reflection page and a learning log, which you can use to keep your own record of professional development.
Duration: 20 hours
Related courses: K03 – Composite Materials in Marine Structures; K01 – Recreational and High Speed Craft; A04 – Project Introduction to Hydromechanics; L02 – Marine Fabrication Methods
Enrol
Study at your own pace and work through the full course material, worked examples and section quizzes. Enrol in K02 – Marine Structural Composites & High-Speed Craft →
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