Deep sea core drilling core removal tool

ROV core removal tool

ROV deep sea core drilling attachments

final batch of 12 ready for deployment
A batch of 12 core catchers for deep sea ROV core drilling

We were commissioned to manufacture a batch of 12 stainless steel core catchers for use by the national oceanography center on their Isis ROV. We were approached with the design concept and shown how it should work on the ROV but the big problem was that trials could only be done when doing the actual job at depth. There were some guesses as to what the material would be at the location but until the dive was done no one was really sure, for the initial prototype and our trials we were given a cinder block as it was the closest material that resembled what they had hoped to find.

Isis Deep Platform ROV
The Isis ROV deep sea platform

The Isis ROV is a lot bigger than it looks in the picture standing at over 8 feet tall it is packed with some very expensive and cool gadgets, inc HD and special cameras, special lighting to a titanium robotic arm!

ROV core removal tool
our initial trials with prototype in cinder block in use by hand applications

We needed to make a working proto type that had to be tested and approved by the client before the final batch of 12 were produced.
The cores were to be core drilled with a diamond core drill bit that would be driven by an underwater air driven motor held in one of the manipulator arms, but the issue was then retrieving the core sample after drilling as it was from deep sediment rock. The idea was to slip the core catcher over the core after drilling, then gently pull and wiggle it with the robotic arm manipulator, it would brake off whilst the teeth would dig in allowing it to be retained in the tube whilst it was removed from the rock bed.
We were given a cinder block as it was thought to be the closest material to the real stuff. 4 holes were cored so we could have a play.

first proto type gripper
the 1st prototype gripper
second proto type gripper
the 2nd prototype gripper
Third proto type gripper
the final protype gripper

We went through three design variations on the gripper before we got it working to how we thought it should work. We then presented it to the client for their own trials in their workshop with the ROV manipulator.

final batch of 12 ready for deployment
The finished assembled batch of 12 core catchers

The top T handles were T shaped as it is best for the robotic arm manipulator to grip onto and use, these were made so they could be unscrewed afterwards and removed so that the core could be slid out. The teeth dug into the core sample so it couldn’t fall our and the teeth were so good it was impossible to slide them the other way.
This was all machined, waterjet cut and welded in 316 grade stainless steel

final gripper design installed in the collection tube
a close up of the finished assembly showing the teeth on the gripper end
ROV core drill core remover in action
this is the view from the command room on the ship looking through the ROV cameras

You can see in this picture some of the camera views from the Isis ROV whilst at the bottom of the sea bed the two lower screens show the core catcher being deployed and in use at the bottom of the sea bed. The design worked perfectly!

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Bronze and brass name plate engraving

Malahne tender engraved bronze name plate close up

We were contacted by G.L Watson yacht designers to assist in producing a bronze engraved plaque as they were having difficulties in getting the deep engravings produced to a good standard.
We were then commissioned to machine and engrave a name plate in bronze for a newly design tender for the Malahne super yacht that was being rebuilt at Pendennis ship yard.
The client was really happy with the results and we were then commissioned by Pendennis shipyard to machine engrave the top step plates for the Bridge Ladders.

Malahne tender engraved bronze name plate
Malahne Tender step plate
Malahne deck top stair tread
Malahne tender engraved bronze name plate close up
A close up of the bronze engraving work we carried out

The Bronze engraved plaque was a tread step for boarding the classic motor launch built for the Malahne classic Super yacht.
With the brief we were given the basic cad file and we then edited and modified it to suit the job and design, then we programmed our cnc milling machine to machine the deep engraving and finished with vapor blasting.
The engraved plaque measured 432mm x 109mm

Close up of bronze engraving
Close up view of the bronze engraving detail showing the crips clean lines engraved

Bronze plate can be difficult to machine nicely as it can be quite soft in plate form making the swarf stringy and creating lots of burrs on the cut edges but we were able to use our skills to over come this.
A close up is shown here with a penny on top for a sense of scale you can see the deep engraving and the quality of the finished part, this is after it had been cleaned and vapor blasted.

A pair of brass stair treads engraved for Malahne's top ladder steps leading to the bridge

With the quality of the first bronze engraved plate for the motor launch pleasing the client. They then commissioned Safire to produce two machine engraved brass stair treads for the main stairs leading to the bridge on the MALAHNE, these were inset into the top steps on the stairs.

close up view of brass engraving showing the clean lines of the plaque

The brass stair tread measured 764mm x 107mm x 6mm thick and had a similar design deeply engraved into it.

Close up of brass engraving
showing the detailed quality of our brass engraving in this close up view

You can see the quality and detail in this close up of one of the brass stair treads.

Malahne rebuilt at Pendennis shipyard
The MALAHNE a classic luxury Superyacht

Originally designed and built by Camper & Nicholson in 1937 the Malahne a 165ft classic motor yacht was completely Restored to exacting standards over a 30 month period.
Here is a picture of the Malahne after the full restoration refit done by Pendennis shipyard

Malahne Tender built by cockwells boat building
A new custom tender motor launch for the MALAHNE classic yacht

The Bronze engraved plaque was a tread plate for boarding the classic  motor launch designed by G.L Watson yacht designers and built for the Malahne by  Cockwells Modern & Classic Boat Building.
At 7.6mtrs in length pictured here on the water with a top speed of 35 knots.

bronze name plate on Malahne Tender built by cockwells boat building
The bronze tread plate on the motor launch
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replacement gear wheel Waterjetcut and machined from aluminum

a close up of a waterjet cut gear cog

Urgent repair on auto pilot gear drive

Our customers yacht was having issues on their way over to the England and whilst they were temporarily berthed at Ocean Village in Southampton they had found a broken gear in their auto pilot system. They attempted a quick glue repair but weren’t confident in it as they had to set of to France in the morning so they asked us if we could make a new gear wheel. Which we did in good time so they could set sale on time.

broken plastic gear wheel
origonal broken gear
new aluminum gear wheel
new gear with slot feature
rear side of new gear

Some before and after pictures here show the gear wheel. You can click on them to see them closer up. The black plastic one has been marked up with red arrows indicating the split.
We had no drawings just the original part to use as a reference for dimensions. Once we extracted the data from the original part we created the cad data for the machines in our workshop.

a close up of a waterjet cut gear cog
a close up of the waterjet cut gear teeth

We waterjet cut the main gear teeth details then machined the slot and bore details on a CNC milling machine.

The gear wheel is quite small, shown here next to a penny for scale you can see the original plastic one and the new one plus a spare just in case!

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