Nestled in the beautiful Arcachon Bay, near Bordeaux in France, the Couach shipyard has been building vessels of exceptional quality since 1897. A manufacturer of motor yachts for leisure as well as vessels for military, customs, and other international government authorities, Couach takes great pride in its engineering standards, build quality, and deep understanding of its customers’ needs.

With a long history of composite construction, Couach has developed highly efficient vacuum infusion processes to build hulls, decks, superstructures, and other components of its vessels. While Couach has traditionally used polyester resin systems, Sicomin has been a key supplier of composite materials to the shipyard for more than 15 years.

For over four years, Sicomin collaborated with Couach’s R&D department as part of a testing program aimed at exploring the benefits of epoxy resin systems in shipyard production. This led to the successful implementation of bio-based GreenPoxy® epoxy resins, the latest addition to Couach’s model range.

Dynamic design with environmental responsibility

Combining comfort, safety, and performance with the best interior layout options and storage solutions in its class, the new dynamic Fly 86/2600 offers an exceptional experience at sea. This 26-meter vessel blends innovative design and layout with durable epoxy composite construction.

Sicomin’s InfuGreen 810 bio-based epoxy infusion resin was used to manufacture the hull, deck, and superstructure of the Fly 86/2600. As a result, the yacht is lighter and more durable, with reduced fuel consumption.

With 38% bio-based content from plant sources, InfuGreen 810 is part of Sicomin’s GreenPoxy bio-based resin range. It was formulated to deliver a sustainable vacuum infusion resin with uncompromising performance.

What is infusion?

Infusion is a manufacturing method used to build boat hulls. All components are placed in a mold and then covered with an airtight vacuum bag. The elements are compacted by extracting the air beneath the bag using a vacuum pump. Finally, epoxy resin is introduced through hoses. This process allows the resin to be applied evenly across the entire surface of the hull.

Seamless transition with the GreenPoxy range

Sicomin supplied all the components required to set up the infusion process. These materials had already proven their effectiveness in several Couach productions prior to this first major application of epoxy resin.

Next, the high-performance E-glass laminate, including sandwich core sections and a range of multiaxial, woven, and stitched fabrics, was assembled in the hull mold.

For the final pre-production step, Couach installed its internally developed monitoring system to ensure vacuum integrity and to track process conditions during the infusion itself.

The infusion of the first Fly 86/2600 hull was carried out by Couach technicians, with Sicomin’s technical team on site to support the process and observe the largest hull produced to date using this advanced bio-epoxy system.

Both Couach and Sicomin were delighted with the results, noting the ease of mixing, the controllable hardener speed, and the excellent fiber wet-out achieved with the new process. Building on this initial success, InfuGreen 810 was also used for the deck and superstructure components, while GreenPoxy 33 bio-based laminating resins were used for secondary bonding during the yacht’s final assembly.

Improved technical performance and composite durability

“Our InfuGreen 810 resin truly provides the optimal solution for infusion in a large structure such as the Fly 86/2600,” comments Philippe Gruaud, Technical Sales Manager for Western France at Sicomin.
“The significantly lower viscosity and enhanced fiber wet-out enable fast, controllable, void-free infusion—especially when using heavy multiaxial and woven reinforcement fabrics. This is not only a more sustainable option; it is the best technical solution for a project of this scale.”

Couach is currently developing a second hull of this type in production.

“With Sicomin’s InfuGreen 810, we were able to build our Fly 86-2600 in a more responsible and eco-friendly way, while producing a lighter, stiffer, and more durable composite structure that reduces our environmental impact. Thanks to the ease of processing, the added confidence of DNV GL type approval, and the technical support provided by the Sicomin team, our production staff—as well as our clients—have truly embraced this latest development. This is certainly only the first in a long series of yachts that will be infused with InfuGreen 810 at Couach.” — Couach

As composite manufacturers continue to integrate bio-based epoxy systems into increasingly large structures, Sicomin is delighted to support innovative shipyards such as Couach. The company looks forward to working with Couach to maximize both the environmental and performance benefits of bio-epoxies across a wide range of leisure and professional vessels in the future.