Designing Composite Hatches: Solving Leaks, Weight & Serviceability

After 32 years, Paikea's original deck hatches were leaking, heavy, and difficult to service. Rather than opting for an off-the-shelf solution with its own compromises, we engineered a complete composite hatch system from scratch. This video details the design philosophy and engineering behind our new hatches, covering: The analysis of why commercial hatches failed to meet our specific needs for offshore sailing. The critical design elements: flush mounting, integrated gutters, and a structural rim that reinforces the deck. The development of custom 3D-printed nylon-carbon friction hinges for ultimate serviceability. How a circular lens reduces weight and heat gain while maintaining strength. The final result: a hatch system that is half the weight of the original, fully flush, and designed to meet ISO/ABS standards. This is applied marine engineering for a real-world refit problem. CHAPTERS: 0:00 - The Problem with Original Hatches 2:15 - Why Commercial Hatches Weren't the Solution 5:30 - The Design Brief: Waterproof, Flush, Serviceable 8:10 - The Structural Rim & Deck Reinforcement 11:25 - Seal Geometry & Gutter Design Explained 14:40 - Custom 3D-Printed Friction Hinges 18:15 - The Lid: Safety, Weight, and Lens Rationale 22:00 - Prototyping & 3D-Printed Molds 25:30 - The Final Weight: 3kg vs 5.7kg (Original) USEFUL LINKS ➜ Supporting blog post https://youngbarnacles.com/engineering-composite-flush-hatches/ ➜ Want to go deeper? Access our detailed composites videos, project files, and community on the Youngbarnacles Members Hub: https://www.youngbarnacles.com ➜ Need world-class engineering for your project? Learn more about our professional design and consultancy services at SYAS Performance: https://syasperformance.weebly.com/ ➜ Free Sailing Library: Check out our free guides on composites, systems, and seamanship: https://www.youngbarnacles.com/resources MUSIC YouTube Audio Library ➜ https://www.youtube.com/