Design Services

At DarkStar Hardware, we do not just manufacture marine hardware — we engineer solutions for demanding environments. From offshore race boats to expedition vessels, we design custom components that are lightweight, durable, and purpose-built.

Whether you are solving a unique rigging challenge, optimizing performance, or integrating new equipment, we bring aerospace-level engineering to the marine world.

Example Project: Custom Titanium Pig Nose for Peacemaker

The component shown above is a custom titanium pig nose designed for the racing yacht Peacemaker, a Ker 11.5 high-performance offshore race boat.

A pig nose, also known as a crane iron, mounts at the tip of the bowsprit and channels the tack line forward, helping ensure smooth sail deployment while minimizing friction.

The geometry of the component was carefully engineered with large-radius curvature to guide the tack line smoothly around the bowsprit. This reduces friction, minimizes line wear, and improves sail deployment reliability, especially during high-load maneuvers and offshore conditions.

Reducing friction at this interface also helps lower peak loads on the line and hardware, improving durability and performance over time.

Because this component sits at the very front of the boat, weight was minimized to reduce pitching moment and maintain optimal performance.

Engineering-Driven Design

Every project follows a rigorous engineering process.

This approach allows us to create stronger, lighter components that improve boat performance while also reducing manufacturing cost, particularly for additive manufacturing processes such as titanium 3D printing.

Capabilities

Design to Production

We can support your project from concept to finished part:

1. Concept and requirements
2. CAD design
3. Engineering simulation
4. Prototype
5. Testing and iteration
6. Production

Built for Demanding Environments

Our designs are used in:

• Offshore racing
• Performance cruising
• Expedition sailing
• Custom yacht builds
• Marine electronics mounting
• Lightweight performance hardware