The patterns are cut using a computer-controlled vacuum cutting table, ensuring accuracy within several thousandths of an inch. At the same time, all reference and ID marks used to assemble the pieces are marked simultaneously using the same machine, with similar accuracy and precision. This results in a superior product with consistent quality, as all future copies of these patterns will be identical.

The cutting table also has the ability to “trace” existing patterns and digitize them into an electronic version for future use. This is an excellent option if you have an outdated or damaged collar that you don’t mind destroying for the patterns. CPI can then adjust the patterns to account for different material stretch rates (such as replacing an old hypalon collar with a urethane one).

Assembly starts by seaming the individual patterns together to form the collar. This is done using specialized heat welding machines to melt the coating of the fabric together. The result is a far more superior bond than any glue is capable of, a bond so strong the surrounding material will fail before the weld does. This is a distinct advantage to urethane products over hypalon, which must be glued together.

The seams are then “taped” using a heat welder and urethane film tape that is color-matched to the fabric. We extrude our own tape using the exact color specs of the fabric manufacturer, putting us in control of color consistency and quality rather than a third-party supplier. Since we don’t use the outer fabric itself to hold air, the tape isn’t the only thing holding air inside the collar. The tape is instead used to add additional strength to the weld and a cosmetic finish. 

The parts that cannot be welded (non-standard D-rings, grommet strips, attachment flaps, vinyl rubstrake and non-marking urethane rubstrake) are adhesive-bonded to the collar using a specially formulated adhesive and hand-rolled. The result is a far superior bond to the urethane material than can be accomplished using hypalon products.

For hybrid collars, CPI fabricates all foam products in-house and doesn’t have to rely on third-party suppliers. This means that we can suggest the most efficient and cost-effective shapes for your boat, or custom-build foam to your specifications and unique profile. Since existing foam lamination equipment and adhesives didn’t meet our requirements, we designed and manufactured our own specialized equipment to heat laminate and hot-wire cut closed-cell polyethylene (PE) foam specifically for RIB boats and hybrid RIB collars.  

Manufacture begins by rough cutting large sheets of foam into blocks to be laminated together. The rough blocks are then heat welded together to form a large blank block of foam. The finished shape is then hot-wire cut from the blank using a computer-controlled cutting table specially made to accommodate the larger blocks of foam required for RIB boats and the special requirements of cutting PE foam.

CPI only uses foam manufactured using a special process so that no holes are poked into the foam to vent gasses left over from the foam blowing process. Common packaging-grade PE foams with these “offgassing” holes absorb far more water and become waterlogged when used in a marine environment.

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