From team lead PJ Shaffer: Phase I consisted of scanning the existing tooling at Allen Boat Company in late 2025. Following the scans, we were able to 3D model a composite "digital Lightning" by piecing together the individual scans and adding laminate thickness and seam detailing in the computer. After reviewing the "mold model", it was decided by the group that we needed scan(s) of existing boats to confirm ABC shapes against measurement stations. Meanwhile, we have been getting initial quotes using the "mold model" for budgeting and timeline purposes.
The team met at Allen Boat Company (ABC) on June 15-16 for Phase II of the scanning of existing hulls from three (3) generations: 15619, 15251, and 14347. These three hulls represent about 30 years of use from the current molds which we scanned in late 2025.
The boats were scanned after being set up in a "measurement" condition - identical blocking, leveled with a transit, etc. From this new data and the tooling scans from the Winter, the team is in the process of modeling the "Allen Lightning" which will be the basis from which we get quotes and purchase future tooling. We are comparing each individual scan and finding the best fit for all the measurement stations to ensure we keep the "new design model" as close to current performance and measurement criteria.
We should have a working model to receive quotes from numerous mold vendors in about a month. From this point, there will be decisions to make on tooling for a "test boat" to ensure the new boat meets ABC and Class requirements. This tooling may be temporary - good for one or two boats - until the new boat is proven and we can produce durable, long-term molds.
I will continue to update FUEL THE FLASH 2030 with notes and photos from our process.
Key Members of the Molds Team
Thomas Allen Jr. -Tom is the owner of Allen Boat Company. He is a Naval Architect and master boat builder. In addition, Tom is a huge supporter of the Lightning Class including servicing the fleet at most regattas. Tom is coordinating all the measurement and post process work through ABC, including historical data and cross-referencing class specs. He is a world class boatbuilder and his product and service are second to none.
Scott Graham: Scott is a highly respected designer and naval architect of many years and has helped the Lightning class out in the past. Scott will be working on the class measurements and applying them to the surfaces we develop. Scott will also advise as he is willing and able on the project.
Andrew William: Andrew's company scanned the molds and has developed surfaces for us to work on from the scans. He is experienced in marine and aerospace industry applications and works with many clients in recreational & commercial industries.
Patrick O'Connor: Patrick is an experienced designer with a naval architecture background. Patrick came and assisted Andrew scan the molds for both Phase I and Phase II. Patrick will help get the final drawing put together to show companies interested in building the molds. Pat has worked at the Allen Boat Company for a number of years so e knows how we build the boats.
David Sprague: David is an International Measurer and active Lightning Class member. He is assisting the process by confirming important class measurement parameters as we review data from multiple scans. In addition, David will assist the class to refine the class specs & measurements to continually improve the measurement process and boat adherence.
PJ Schaffer: PJ is a mechanical engineer with 35 year's experience in the recreational marine industry. He is currently the Engineering and ISO Manager at New England Boatworks in Portsmouth RI. PJ has done many projects like this in his job & will work with the companies that will build the molds.