The build of Endurance continues to move forward, with work now officially underway on one of the most distinctive elements of the vessel: the Endurance pilot house. Engineered for performance, control, and visibility, the pilot house is a showcase of design precision and purpose — blending advanced composites with a pilot-first approach.
A Bridge Designed for Total Control
Captain James Wakeford, drawing from both marine and aviation experience, envisioned a bridge where essential systems could be monitored and controlled from the helm — without moving from the pilot seat.
“Flying a helicopter teaches you to manage everything from a fixed position. I wanted to bring that level of immediate access and situational awareness into Endurance,” says James.
This vision led to a practical yet sophisticated layout. Fuse panels are fully visible and accessible from the seated position, and various systems will be controlled directly through their fuses — removing the need for extra switches and simplifying fault diagnostics underway.
From 3D Design to Real-World Build
The Endurance pilot house began life as a detailed 3D CAD model, designed by naval architect Camilo D’auria. His focus on visibility and uninterrupted line-of-sight from the helm played a defining role in the final form.
Working closely with James, Camilo translated concept into reality — developing digital designs that optimise sight lines, spatial layout, and operational flow. These CAD files are then sent to our composite builders, where the transformation begins.
Precision Moulding and Composite Craftsmanship - STAGE ONE
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To support the potential for customisation, the roof and aft moulds were engineered with a split to allow for an optional 1-metre width extension, available on the wide-body version of the vessel.
Each mould is CNC-cut from high-density foam based on Camilo’s CAD files. The foam is then filled and spray-coated to achieve a flawless, glass-like surface, ready for the composite layup process.
Camilo has also developed a comprehensive laminate specification, detailing carbon fibre layering, foam core densities, and the location of reinforced backing plates for hardware such as handrails and navigation lights. These early structural decisions will ensure durability, performance, and straightforward outfitting in later stages.
Watch our behind the scenes video of Stage 1
To support the potential for customisation, the roof and aft moulds were engineered with a split to allow for an optional 1-metre width extension, available on the wide-body version of the vessel.
Each mould is CNC-cut from high-density foam based on Camilo’s CAD files. The foam is then filled and spray-coated to achieve a flawless, glass-like surface, ready for the composite layup process.
Camilo has also developed a comprehensive laminate specification, detailing carbon fibre layering, foam core densities, and the location of reinforced backing plates for hardware such as handrails and navigation lights.
These early structural decisions will ensure durability, performance, and straightforward outfitting in later stages.
Building the Pilot House: STAGE TWO
With the design work and mould preparation complete, the project moved into Stage 2: the construction of the Endurance pilot house.
The carefully prepared moulds provided the foundation for the composite build. Using the laminate specification developed by Camilo D’Auria, the team began laying up the structure, incorporating the specified carbon layers, foam core densities and reinforced backing plates for equipment and fittings.
At this stage, the focus shifted from the precision of the digital model to the craftsmanship of the physical build. Each layer contributes to the strength, stiffness and overall performance of the finished pilot house, while the moulds ensure that the complex geometry developed in CAD is accurately translated into the final structure.
The split roof and aft moulds also retain the flexibility built into the original design, allowing the pilot house to accommodate the optional 1-metre width extension for the Endurance wide-body version.
This is where the pilot house really starts to take shape — transforming from a 3D concept and a collection of CNC-cut moulds into a finished, fully integrated part of the vessel.
This is just one stage in the journey. Keep watching as the pilot house evolves from a bare composite structure into a finished, fully fitted-out helm — and see how the ideas developed in CAD ultimately come together on board Endurance.