Through years of effort and many generations of vessels, Nautic Star has evolved a superb hull form for high-performance patrol, rescue, research, commercial and recreational craft. Compared to a traditional deep vee hull, the distinctive deep forefoot and steep bow stem offers many advantages.

Due to the plumb bow, Nautic Star vessels typically have a water line length (WLL) about 8% longer than a vessel with a traditional stem profile. Without increasing the overall length of the vessel, this extra water line length reduces hull flow resistance, helps the vessel plane on the water more quickly, and reduces bow rise, trim changes and pitching. The maximum waterline beam now having the ability to be carried approx. 15% further forward without reducing the deadrise of the vessels’ hull.

The substantial increase in the forward volume of the hull translates into better seakeeping and a more comfortable ride. The stem cuts through the waves rather than bounce over them like a traditional bow. In addition, the extra buoyancy gives a safer and more comfortable ride in following seas because the tendency to bury the bow is much reduced compared to a traditionally raked bow.

Volume of Nautic Star bow compared to a traditional hull form


Nautic Star’s design philosophy is our boats must be safe, high-performing and aesthetically styled. The build process must support this philosophy. As our design evolved, so too has our manufacturing process. Our skilled team pay attention to every detail and build an exceptional boat.

Nautic Star design has evolved over many years to be the outstanding vessel it is today. From concept sketches to CAD drawings and prototypes built and tested, all designs at Nautic Star involve naval architects and marine surveyors to ensure all designs meet regulations and marine survey requirements.

After certification of the design, CAD files are sent to a specialist facility in Adelaide to accurately cut the aluminium into the required sections. With all the cut metal delivered to Nautic Star, our skilled welders commence assembly of the hull structure. The work is done in the purpose-built fabrication shed at Nautic Star premises. First the hull structure is fabricated upside down, then turned right-side-up for deck and superstructure fabrication.


The second phase of the build is blast and paint. First, the fabricated hull is sent to a specialist company in Adelaide and the entire structure grit blasted. This removes weld residue and readies the boat for priming and painting.

A corrosion inhibiting epoxy primer is applied to the hull within six hours of blasting to ensure oxidisation does not get trapped beneath the paint, which could later cause corrosion. Then comes many hours of hand sanding and filling to fair the hull to a smooth finish that is then painted according to the customers’ colour scheme requirements.

As part of Nautic Star’s approach to quality, considerable research has been undertaken to find the best paint system to use to present and preserve the vessel. Nautic Star vessels are painted using the International Paint system including the AWL Craft 2000 topcoat, which gives a high quality, durable, easily polished and repairable finish. As well as providing top quality primers and topcoats, the after sales service available from International Paints ensures Nautic Star boats can remain in excellent condition for many years.


One of the defining traits of any Nautic Star vessel is the unwavering quality and attention to detail. Nautic Star understands corrosion protection depends on careful material and fitting selections, as well as methodical and fastidious application of paints and isolation of dissimilar metals.

Every hole larger than 12mm and every instrument cut-out is completed prior to blasting and painting to ensure complete coverage of bare metal. The meticulous painting process includes application of corrosion inhibiting epoxy primer within six hours of blasting to ensure oxidisation does not get trapped beneath the paint, which could later cause corrosion.

Mounting holes smaller than 12mm are drilled after painting and then cleaned, prepared and coated with Duralac anti-corrosion compound. All fittings are mounted with nylon washers, Loctite MS polyurethane adhesive and stainless-steel bolts to effectively create an adhesive ‘gasket’ to separate materials, exclude water and maximise the life of the vessel.

Where aluminium mounting plates are screwed into the deck, countersunk nylon inserts are used to completely eliminate contact between stainless steel and aluminium.


The painted boat is then moved to the specially designed outfitting bay at Nautic Star. The outfit process involves installation of outboard motors and controls; fuel tanks, line and filters; batteries and electrical switching and cables; surveillance and navigation electronics; radios; seats and cabin furnishings; deck cleats, handrails and all other fittings needed to complete the boat.

A specialist electronics technician works with the Nautic Star team to ensure the navigation, radios and other electronics equipment is installed correctly in accordance with the approved drawings. The furnishings installed in Nautic Star boats is made onsite by the highly skilled and multi-talented team. The team manufacture seats, deckhead linings and hull collars. All our vessels regardless of whether they are commercial or recreational are filled with survey approved buoyancy foam from bow to stern.  Access to this foam is available via a deck sole which extends from the stern through to the anchor locker bulkhead which is screwed down and sealed.


As with any quality manufactured machine, the final activity is to test and trial the vessel. For Nautic Star vessels this involves different people who are specialists in different checks to certify:

  • the vessel has been built to the approved design.
  • all installed equipment operates to specification.
  • the vessel meets all Australian Maritime Safety Authority (AMSA) regulations, including safety equipment for commercial vessels
  • at sea the vessel performs to Nautic Star’s high standards.

If the customer has a Function and Performance Specification, Nautic Star conducts a trial against each demonstrable requirement and provides Objective Quality Evidence to verify the vessel meets requirements. This data is provided to the customer for their records.


Nautic Star design and build our own trailers. Like our boats, the design of Nautic Star trailers is functional and innovative, and the build quality is first class. The design of the trailers has been approved by a naval architect. The trailers are designed in accordance with Australian Design Rules (ADR), so they can be registered for road use in all States.

The trailers are designed for easy launching and recovery. They are also designed to be light weight, durable and require minimum maintenance. The trailers are manufactured from aluminium (90%), stainless steel (5%) and galvanised steel (5%). These materials were selected to reduce the weight of the trailer as well as reduce corrosion. The design keeps the gross mass of a 7m vessel and trailer below a 3,500kg weight limit for towing and below 4,500kg for an 8m vessel.  The axle system is manufactured by Trojan and incorporates a torsion suspension system. The torsion rubber provides a smooth ride over undulating and unsealed roads. The system is also much less prone to rust than steel leaf springs. All hubs are fitted rotors and stainless-steel callipers. The trailers have a Hydrastar electric-over-hydraulic brake system, which provides strong braking power and break-away compliance.

The wheels use ‘bearing buddies’ to give them the best protection when immersed in salt water as well as a simple approach to supplying grease in the bearings to alleviate the maintenance burden. Hella marine electrical fittings are used, which are fully immersible in water.

Nautic Star also design and build 6, 7and 8.5 tonne ADR compliant trailers. We have been working with a heavy trailer component manufacturer based out of Queensland to develop what we believe is the most marinized axle, suspension and brake assemble available on the market for trailers over 4.5 tonne. Our axles are galvanised with the entire brake assembly being stripped down, with all components that can be zinc coated, we have zinc coated.  All bushes are replaced with bronze bushes, all U-bolts and nuts are zinc coated.  The leaf suspension system, rocker arms, hangers and hanger straps have also been disassembled and galvanised or zinc coated. All fasteners where possible have been replaced with stainless steel fasteners.  Also standard in our ADR compliant trailers, is an integrated fresh water wash down system.  This system makes the fresh water flushing of the trailers drive train thorough with no potential for components to not be properly washed down. All that is required is the connection of a garden hose on the front of the trailer, 1 for each pair of wheels. In addition to this we can offer a remote greasing system to grease the 20/30 grease points which are situated on the drive train. The remote greasing point will be placed on the forward end of the chassis which makes for easy greasing of components. We will also offer in lieu of the remote greasing system an automated greasing system.  This greasing system will automatically grease all 20/30 grease points on the trailer at designated intervals and quantities set by Nautic Star when the trailer is connected to the vehicle.