Gibbs Humdinga & Phibian

Some projects demand more than conventional engineering solutions. The Gibbs Humdinga was one of them. Tasked with transforming an ambitious amphibious vehicle prototype into a repeatable manufacturing programme, Kamm overcame significant challenges in materials, tooling and structural complexity. The result demonstrated the value of approaching seemingly impossible manufacturing problems with ingenuity and determination.

Overcoming the Challenges of Large-Scale Carbon Fibre Structures

Kamm was commissioned to develop and manufacture the composite structures for the Gibbs Humdinga, an amphibious vehicle built around a 6.7-metre carbon-fibre hull. Inheriting tooling originally intended for prototype manufacture, the programme presented significant challenges involving thermal expansion, complex laminate construction and dimensional stability. Kamm developed new manufacturing processes, cure sequences and tooling solutions to overcome these limitations. A subsequent production phase introduced an innovative vacuum-infused carbon-fibre tooling system, avoiding the need for conventional tooling manufacture while improving repeatability and reducing costs. Through these developments, Kamm reduced the production time for a vehicle set from 16 weeks to just 2.5 weeks, with an estimated £1 million saving in tooling costs. The experience subsequently supported the manufacture of a 10.5-metre composite hull for the Gibbs Phibian.

  • Development and manufacture of a 6.7-metre structural carbon-fibre hull
  • Complex pre-preg laminate construction incorporating up to 37 layers of 400gsm carbon fibre
  • Development and management of 12 individual cure cycles for a single hull
  • Innovative vacuum-infused carbon-fibre tooling, avoiding approximately £1 million in conventional tooling costs
  • Reduction in vehicle-set production time from 16 weeks to 2.5 weeks
  • Precision assembly fixture development, eliminating significant post-assembly machining costs
  • Manufacture of a 10.5-metre composite hull for the Gibbs Phibian
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