42' Mono Catamaran
Full-frame aluminum catamaran — built from scratch
Project Overview
A ground-up aluminum frame fabrication for a 42-foot mono catamaran. This wasn't a repair or a retrofit — it was a complete build from raw aluminum plate and extrusion to a finished structural frame ready for outfitting.
The Challenge
Building a catamaran frame from scratch demands absolute precision in hull symmetry, structural integrity at every weld joint, and tight tolerances for the twin-hull geometry. Any misalignment compounds across the 42-foot length, so every cut and tack had to be dead-on from day one.
The Solution
DolFab's team used full 3D CAD layouts to template every frame member before cutting. All structural welds were multi-pass TIG in marine-grade 5086 and 6061 aluminum. Hull symmetry was verified at each assembly stage with laser alignment. The result: a frame that met class survey standards with zero rework.
Project Details
- Vessel
- 42' Mono Catamaran
- Material
- 5086 & 6061 Marine Aluminum
- Process
- TIG Welding, CNC Cutting
- Scope
- Full Frame Fabrication
- Location
- Fort Lauderdale, FL
Need Similar Work?
Every project starts with a conversation. Tell us about your vessel and what you need — we'll handle the rest.