Regent Craft

Moore Brothers Company Aims to do More Aerospace Prototyping

Not everyone can immediately see the similarities between the aerospace and marine industries, but there are more than one might think.

“In the marine industry, we benefit not only from unique and original ideas but also the expectation of producing composites at a very rapid pace,” says Oliver Moore, co-owner and co-founder of Moore Brothers Company.  From experience, the Moore Brothers team appreciates their agility is an asset when pitching to prototyping in other industries such as aerospace.

Specifically, what Oliver is referring to is the marine industry’s ability to build the lightest, fastest boat possible that won’t break under extreme pressure. Sailing teams that race in the America’s Cup have three years to create that boat: from starting with an idea to having a vessel that can reach speeds well over 40 knots. “The aerospace industry looks at that and thinks it’s impossible.” Says Oliver. “Each competition has a new design rule and teams have 3 years to design, build and learn to sail their best effort to challenge for the Cup on a set date.”

By using a tried and true model, the team at Moore Brothers is well equipped to produce a range of one-off composites within specific tolerances - and fast. “We’re never building the same thing twice.” Says Oliver, “which means our team has to be agile, creative and of course, highly-skilled.”

For the most part, America’s Cup boats and rockets are made out of the same materials these days, but, according to Oliver, many of the aerospace factories just aren’t built to produce prototypes on the schedule that some companies want them.

Due to the countless certifications that a company needs in order to manufacture aerospace parts, most companies take on bigger and multiple contracts in order to cover the costs of certification, production and workforce. That means long wait times for companies that are trying to get funding for their ideas. For prototyping, that just doesn’t work. Companies want their prototypes ASAP.

“In the marine world we are processing fully custom composite system jobs from design through install on the order of 6 to 12 weeks.  Be they masts, rudders or ballast systems.  You need to have very strong but flexible systems in place to be able to do that at a high level.  The marine industry gives us the opportunity to build and hone those systems which are directly transferable to the industrial/aerospace world.” 

The U.S. aerospace industry is the largest in the world and is expected to have a Compound Annual Growth (CAGR) of 2.4% between 2023 and 2028. 

The green race in aerospace

Many people might think of your traditional airplanes and rockets when the word “aerospace” is brought up, but with the push to reduce carbon emissions to combat climate change, the amount of companies focusing on building electric planes and helicopters is also growing. These companies need innovative composite companies to help them build prototypes. “We were already very creative in how we approach problems,” says Oliver, which is why it felt like a natural fit to start working with aerospace companies. 

Recently, Moore Brothers Company helped design and build a quarter-scale model of the wing-in-ground effect vehicle for REGENT that flew over Narragansett Bay last year. Although REGENT’s electric seaglider is not considered to technically be an aircraft (it is a maritime vessel), it will fly just above the water utilizing the reaction of air against the surface of the water. That being said, it does fly and REGENT has signed aviation contracts worth billions of dollars with companies around the world.

In April, Moore Brothers Company built a full-scale mock up of what will ultimately be a passenger carrying glider. The following month, REGENT announced that Moore Brother Company will be the main partner in creating the necessary components for the 65-foot carbon composite wing and hull for the company’s full-scale seaglider prototype. Oliver said that they most likely got the contract because they could produce what REGENT wanted at a reasonable price and on the company’s timeline (they want to have passenger-carrying vessels in operation by 2025).

Moore Brothers Company currently employees over 40 design engineers, composite and machine techs and management staff. Beyond that, there is plenty of talent to pull in for larger projects. When it came to the REGENT Project, Moore Brothers was contracted to produce the majority of the components for the company’s first full-scale prototype. Oliver brought in additional talent and manpower by contracting Zack Parent and the team at Ocean State Composites to manage fabrication of the vessel’s hull - a 55ft fuselage - by working onsite with the Moore Brothers Team. “We are excited to be part of these projects with Moore Brothers Company,” said Zack, noting that crucially, “we all work well together as a team.” Their experience in fabrication within leading America’s Cup syndicates and other racing programs made Zac and Ocean State Composites a crucial part of delivering high-quality components on time and at the required scale. 

“We work with our community in a collaborative way” says Oliver, which, he says is more similar to how larger contracts are fulfilled in Europe: utilizing sub-contractors when needed. 

Not forgetting their maritime roots

Although the Moore brothers plan on continuing to expand their business in the aerospace sector, they are not forgetting their roots. “Maintaining our marine industry business and progressing alongside valued clients will only strengthen our ability to service those in other industries.” Says Oliver.

Moore Brothers and Ocean State Composites join forces to get the job done

MOORE BROTHERS AND OCEAN STATE COMPOSITES TEAM UP TO GET THE JOB DONE

After two years of working with REGENT Craft, Moore Brothers Company was selected to build their first full-scale prototype vessel in May of 2023. REGENT is developing a range of all-electric seagliders, flying vessels that combine the speed, comfort, and navigation systems of an aircraft with the convenience, maneuverability, and affordability of a boat. At 55ft long with a 65ft wingspan, the full-scale composite prototype vessel would represent the company's flagship design and perform it's first crewed testing. Moore Brothers worked closely with REGENT through their initial development and supported their establishment in Rhode Island, and as a young company now earning contracts for larger projects, founders Oliver and Sam Moore quickly acknowledged the need to expand.

"When it came to acquiring additional talent, it was important we did it in a sustainable way," said Oliver, who led the decision to sub-contract another local company, specialists Ocean State Composites, to lead fabrication of the REGENT hull. The vessel hull is a 55ft fuselage, built to critical weight specifications that require technical out-of-autoclave prepreg lamination skills.

Working collaboratively with the community empowers Moore Brothers and its neighbors to support big jobs with greater strength and experience, with less of the risk that comes with rapid onset growth. "Ocean State Composites has brought the highest level of composite craftsmanship to the project here at Moore Brothers," Oliver continued. "We've enjoyed working with them and would like to think the partnership has been beneficial for all parties - We’ve pushed each other."

In addition to Moore Brothers' project management and engineering teams, staff of 20 core builders and 15,000sq ft facility, the Ocean State Composites brought 25 of the industry's top talent and the large-scale fabrication expertise of it's owner, Zack Parent. In uniting under a common goal, the teams have proven their hardworking nature... true to people who have worked the waterfront for many years and carried Rhode Island’s marine trade proficiency to clients and countries overseas.

Zack and the team at Ocean State Composites have worked at Moore Brothers to manage the hull build and "pitched in" in more ways than one, often stepping in to help problem solve and make recommendations. Indicative of the project's nature, the REGENT build continues to be a collaboration among partners.

"At Ocean State Composites, we've been building a great crew over the last few years. Having some of the best guys in the game is what makes my company tick,” said Zack, who recently opened his own facility on Broadcommon Rd. "The opportunity to join Moore Brothers on this new and exciting endeavor is a true privilege and we don't take it lightly. Their team brings years of experience designing and executing at a high level. The meshing of the crews has been seamless, and we look forward to a positive future for the collaborative.”

Moore Brothers Company is currently hiring composite technicians. Email us directly at office@moorebro.co or view and apply to one of our open positions.

U.S. Senator Jack Reed Visits Moore Brothers Company

From left: Oliver Moore (Moore Brothers, Director), Billy Thalheimer (Regent CEO), Senator Jack Reed, Michael Klinker (Regent CTO), Sam Moore (Moore Brothers, Director)

U.S. Senator Jack Reed visited Moore Brothers Company in July for a tour of our facilities. Oliver Moore spoke to Senator Reed about the current projects, including the large-scale REGENT project.

REGENT is developing a line of seagliders that operate exclusively over water, traversing the sea in one of three modes: hull, hydrofoil, or flight in ground effect. Moore Brothers Company built the REGENT prototype, which underwent successful sea trials last year. MBC is currently building the first full-scale craft for REGENT.

REGENT plans to conduct passenger-carrying sea trials in 2024 and is targeting a 2025 entry date for its new line of seagliders for commercial use. 

Senator Reed, a member of the Appropriations and Armed Services Committees, has worked at the federal level to make Rhode Island a leader in maritime technology.

“We are constantly looking for ways to strengthen Rhode Island’s blue economy.  This is innovative technology that could make coastal transportation more efficient, eco-friendly, and cost-effective.  I’m pleased to see REGENT bringing more jobs to Rhode Island and tapping into the state’s composite manufacturing and research network,” said Senator Reed in a press release on his website.

“It was exciting to share with Senator Reed our current projects, including the large-scale REGENT project,” said Co-owner and co-founder of Moore Brothers Company, Oliver Moore. “The partnership between us and REGENT is one that we hope to sustain for years to come, and hopefully attract other innovative partnerships as well.”