The Duflex Kit Process


Duflex is a high quality composite panel made to order under controlled conditions. The skin laminates can be timber, glass, carbon or kevlar in epoxy and the core materials can be virtually any commonly employed material including PVC foam, end grain balsa or aramid honeycomb.


The panel shapes are defined by routing 2.4m x 1.2 m panels which are joined on the build site to create the full size and shape of the required panel. They have a unique scarf join in the long edge which eliminates the need for glass tapes on that edge, substantially reducing the taping and fairing work.


Duflex panels have a strength to weight ratio that is difficult to match with conventional laminating techniques. The panels have a peel ply finish which requires very little preparation as a finished surface.

The primary features of ATL’s DuFLEX kits are;

•High quality composite panels manufactured under controlled conditions to achieve a consistent laminate with a high fibre ratio.


•The proprietary Z join that makes joining the panels a breeze and avoids the need to tape the panels on the long edge.


•A streamlined process managed by ATL Composites that integrates design, engineering, panel nesting, laminating, and delivery to your workshop door, combined with technical support and service that is unsurpassed in the industry.


 For a full description of DuFlex kits, materias and process visit:




We have a highly productive working relationship with ATL Composites that goes back to 1986 when the then manager of Adhesive Technologies in Sydney, Graeme Bird, built the 8m trimaran ATL to test and promote Durakore and the West Resin System.


ATL (the trimaran) has had a number of different owners and different names over the years and has an impressive racing history including winning the Queensland Multihull Championships in 2010. She is still actively being campaigned on the race circuit today (2015).


ATL have been developing and selling the DuFLEX kits since 1994. The kits are used enthusiastically by amateur builders, professional yards and even production builders of motor yachts and sailing yachts, multihull and mono.


All of our current designs are ideally suited to construction from DuFLEX kits. Each kit is unique to your project and designed to suit your requirements.

The DuFLEX kit is a comprehensive package of the composite materials required to build the complete structure. It includes the forebeam, catwalk, the dingy/solar bar on the aft beam, all the bulkheads, cabin soles, wing frames and berth panels.


The interior kit can be included if requested, and it is more economical to order it with the rest of the kit because some of the smaller pieces can be nested amongst the main kit components, however if you are not sure about the layout it is better to leave the interior until the construction is well advanced.


Some owners/builders order the interior kit separately so a lighter laminate can be used (such as ATL’s Featherlight which has a phenolic impregnated paper honeycomb core) , however the weight saving is very small relative to the total boat weight.


The kit components are:

 1. Panel Kit

CNC routed flat panels laminated under pressure with epoxy/glass (or carbon) skins and PVC foam core. The panels have ATL’s unique Z join on the long edge. The panels are cut to definitions provided by the designer. They may include panels for the interior components and other custom components requested by the owner. Our standard kits include the forebeam, the solar bar/dinghy rack, the catwalk, and either the dagger cases or the panels for the fixed keels.


2. Material for strip planking Hull Bottoms, usually foam cored Durakore. It can be left out of the kit if the hull bottoms are being built in cedar strip or another method.


3. A set of plywood mould frames and cradles CNC routed to the designer’s specification.


4. Epoxy resins and hardeners. Usually two different types, a laminating resin and a general purpose resin. The hardeners can be tailored for cure times depending on the climate you are working in.


5. Three types of powders for filling, fairing and gluing purposes.


6. Additional fibreglass and usually carbon for reinforcement in high load areas and components such as chain plates.


7. Fibreglass tapes, peel ply, glue cartridges, mixing gun and other small items such as squeegees.

For a full description of Durakore material and process visit:


To enquire about availability and pricing of our DuFLEX kits contact us here: