1.Design & Initial Cutting The process begins long before any metal is cut. Every boat is designed using Computer-Aided Design (CAD) software . Once the design is finalized, the aluminum components are precision-cut using an advanced laser cutting line . This CNC-controlled process ensures that every piece is cut to exact specifications for a perfect fit .
2. Hull Formation & Welding
Shaping:
The cut aluminum sheets, made from high-tensile marine-grade 5083 aluminum , are shaped using a brake press to create features like chines and planing strakes .
Welding:
The shaped pieces—including the hull sides, floor, and transom—are then welded together. This is done using pulse MIG welding, often performed by highly experienced welders and augmented by robot welding for consistency and strength .
3.Surface Treatment & Powder Coating
To protect the hull from the marine environment, it undergoes a rigorous finishing process :
Acid Bath/Chemical Pre-treatment: The welded hull is submerged in an acid bath to clean and prepare the aluminum surface for coating .
Powder Coating: The hull is then moved to an automatic powder coating line . In this eco-friendly process, the paint (in powder form) is electrostatically sprayed onto the hull .
Baking: Finally, the coated hull is baked in a large oven. This causes the powder to melt and fuse into a smooth, durable, and uniform finish . This in-house line is exclusive to Highfield and helps capture and recycle excess powder, reducing environmental impact .
4. Assembly & Rigging
With the hull complete, the boat moves to the final assembly stage.
Tube Bonding: The inflatable tubes, made from top-quality materials like PVC or ORCA® Hypalon , are bonded to the aluminum hull using high-strength adhesives .
Component Installation: All other components are installed. This includes the console, seats, fuel tank, and any other fittings like the aluminum arch or anchor holder. Remarkably, even the detailing of handrails and the production of cushions are carried out entirely in-house .
5. Quality Control & Testing
Quality is embedded at every stage, but finished boats undergo rigorous final inspections. Every Colton boat is tested to strict ISO standards before leaving the factory . This includes testing fabric strength, seam integrity, and air tightness . The aluminum itself is sourced and tested for strength and alloy quality in batches .
