🎧Life on the ocean wave

For nearly forty years, Pendennis Shipyard has established itself as a global leader in building, refitting, and restoring fully bespoke superyachts from its 14-acre waterfront site in Falmouth, Cornwall. The esteemed shipyard employs over 550 skilled craftspeople across various trades, including machining, fabrication, electrical work, and joinery, all working within cutting-edge facilities that feature a 150m dry dock, two 90m construction halls, and an enclosed non-tidal wet basin.

The company’s machining operations have been consolidated into The Digital Manufacturing Centre (DMC), a facility capable of producing everything from 2mm diameter pins to components for 8m booms. This centralisation has enhanced their capabilities, with Workshop Manager Jack Chuter now able to efficiently coordinate both replacement parts for existing vessels, which account for 60% of the centre’s work, and collaborate with surveyors and designers on new components that must be both functional and aesthetically pleasing.

Pendennis started their CNC journey in 2015 with an XYZ SMX 4000 bed mill, chosen specifically for its conversational programming capabilities while keeping manual operation options. “We didn’t want to jump straight into full CNC machining,” explains Jack. “The SMX 4000, with its conversational programming and manual capability retention at a great price point, was perfect for developing the workshop.” This strategic approach proved successful, immediately enhancing both efficiency and accuracy while broadening the scope of parts that could be manufactured.

The success of this initial investment led to the purchase of a ProTURN SLX 555 x 1m CNC lathe the following year. However, as demand for superyacht refits continued to grow, Pendennis recognised the need for more advanced machinery to meet increasingly difficult requirements, including tighter deadlines and more demanding materials.

Recent additions include the XYZ 1100 HD vertical machining centre and XYZ TC 400 slant bed turning centre, investments driven by evolving industry demands. “We needed machinery that could tackle everything from aluminium and phosphor bronze through to 316 stainless, 17-4 Duplex and Nitronic 50-60 with ease,” notes Jack. “Reducing cycle times was important, but equally crucial was developing multi-tasking capabilities by running machines unattended during production.”

The XYZ 1100HD, with travels of 1.1m by 610 by 610mm in X, Y, and Z axes, proves ideal for machining tough, sea-resistant materials. Its hardened box section slideway construction and BT40 spindle taper, combined with a 21kW spindle motor delivering 5-10,000 rpm, provide the power and versatility needed for superyacht applications.

Similarly, the XYZ TC400’s 400mm maximum turning diameter, 600mm turning length, and 78mm bar capacity provide flexibility for both single components and larger batches. Its 32kW spindle motor, which delivers a maximum of 3300 rpm, has already proven invaluable for the workshop’s expanding needs.
The DMC employs three highly skilled machinists alongside apprentices who benefit from Pendennis’s award-winning training scheme. This mix of manual XYZ lathes for simple work and apprentice training, Prototrak-controlled machines for one-off and simpler parts, and Siemens-controlled equipment for complex, high-volume work creates an ideal learning environment. Programming combines CAD-CAM for 90% of milling tasks with conversational software for turning operations.
Investment in XYZ machinery, alongside CNC waterjet and 5-axis router equipment, has not only enhanced in-house capabilities but increased the shipyard’s appeal to young talent. With nearly a third of the workforce having completed apprenticeships at Pendennis, growing their own expertise remains integral to success.