Built to Perform: The Aluminum Expertise Driving EBDG’s Vessel Innovation
Aluminum isn’t just a material—it’s a strategic solution. From passenger ferries and shallow-draft workboats to high-speed utility vessels, we’ve spent decades engineering aluminum platforms built to perform in the world’s toughest marine environments. Our work blends technical precision, real-world experience, and a deep understanding of aluminum’s unique challenges and advantages. Whether the goal is speed, durability, or mission-specific performance, we deliver aluminum vessel solutions that lead the industry in strength, safety, and versatility—all from the team at EBDG.
Engineering Resilience: Proven Aluminum Vessel Designs
Built for performance, not just weight savings, aluminum vessels must withstand demanding environments while delivering strength and versatility. Elliott Bay Design Group applies this philosophy across a wide range of aluminum designs, delivering performance-driven solutions for operators in remote, high-speed, and mission-critical settings. Backed by decades of engineering expertise and real-world insight, each vessel reflects a commitment to strength, speed, and reliability where it matters most.
RUGGED RELIABILITY: 44’ LANDING CRAFT
Built to service Alaska Wildland Adventures' remote lodges, Aligo Point is a USCG-certified aluminum landing craft designed for versatility and endurance. It can carry up to 30 passengers or 10,000 lbs of equipment, with reinforced truck paths, a robust bow ramp, and removable seating—all engineered for performance in unforgiving terrain. Originally developed by Coastwise Corporation (now a division of EBDG), this design remains part of our active design library.
ENGINEERED FOR THE EXTREME: 62’ LANDING CRAFT
Arctic Solution operates in slush-ice and shallow-draft conditions along Alaska’s North Slope. This aluminum landing craft is designed for direct beach landings and adaptable cargo/passenger configurations. It exemplifies EBDG’s “design for environment” approach—purpose-built for the demands of Arctic operations. Originally developed by Coastwise Corporation (now a division of EBDG), the design remains part of our active design library.
MISSION-READY: 40’ UTILITY BOAT
Designed in collaboration with Kvichak Marine for the U.S. Navy, this high-speed welded aluminum monohull features waterjet propulsion and delivers speeds up to 40 knots. Built for rapid personnel deployment and cargo handling, it reflects the strength and agility required for military operations.
HIGH-SPEED INNOVATION: 120-PASSENGER FERRY
Contract notional design for North Carolina Department of Transportation (NCDOT), this 120-passenger vessel is in service between Hatteras and Ocracoke to improve the vacation experience for visitors to the Outer Banks.
MULTI-ROLE PERFORMANCE: 68’ EXCURSION VESSEL
EBDG designed the GUARDIAN to serve as both an open excursion vessel and emergency responder at Niagara Falls. Built to Transport Canada standards, the 68’ aluminum vessel carries 144 passengers, features waterjet propulsion, and can assist a 700-passenger vessel against strong currents.
COMMUTER-TESTED: 78’ HIGH-SPEED CATAMARANS
Originally designed for whale watching in Alaska, these 78-foot high-speed catamarans were later adapted for 150-passenger commuter service in New York Harbor. Built by Allen Marine in Sitka, Alaska, the vessels feature a robust structural design and quad waterjet propulsion for enhanced reliability. A total of 19 commuter vessels were delivered to NY Waterway and have been operating successfully for over 20 years, safely transporting thousands of commuters each day. Originally developed by Coastwise Corporation, now a division of EBDG, and part of our active design library.
Meet the Experts Powering EBDG’s Aluminum Innovation
EBDG has built a strong reputation for its work in aluminum vessel design, offering a blend of technical excellence, field experience, and innovative solutions for clients across commercial, governmental, and industrial marine sectors. From high-speed passenger vessels to shallow-draft landing crafts, EBDG’s aluminum work spans a wide range of operational needs particularly where weight savings, speed, and corrosion resistance are critical.
EBDG’s aluminum expertise is rooted in a team of highly experienced professionals who combine practical know-how with advanced engineering skills. From inspections and fabrication oversight to vessel design and structural analysis, our people lead the industry in quality, innovation, and performance.
JIM TOWERS, PE - PRINCIPAL IN CHARGE
With 50 years of marine engineering experience, Jim is one of EBDG’s most seasoned leaders. As a Principal in Charge, he oversees complex vessel and shipyard projects with a strong focus on quality control and aluminum fabrication standards. Jim has led numerous aluminum vessel builds and repairs throughout his career and served as chair of the ASTM Marine Aluminum Committee B07. He was instrumental in the development of ASTM B 928 Standard Specification for High Magnesium Aluminum Alloys for Marine Service and Similar Environments. His knowledge of aluminum welding codes, fabrication techniques, and shipyard production processes has made him a trusted advisor to fabricators and operators across the country.
PAT EBERHARDT, PE - PRINCIPAL IN CHARGE
Based in Alaska, Pat brings over 40 years of aluminum vessel design experience and before joining EBDG as a Principal served as the founder and President of Coastwise Corporation. His firm was renowned for designing high-speed aluminum vessels tailored to Alaska’s remote and rugged environments. Pat’s body of work includes more than 25 aluminum catamarans—many of which were among the first of their kind in the U.S.—used for commercial transport, whale watching, and shallow-draft utility operations. His “design for environment” philosophy, focused on performance and durability in cold-weather and isolated regions, continues to guide EBDG’s aluminum strategy and innovation.
THERESA FIELDING, PE, NAMS-CMS, CWI - SENIOR NAVAL ARCHITECT
Theresa is a Certified Welding Inspector and Professional Engineer with more than 20 years of marine industry experience. She provides welding procedure development, quality control oversight, and structural inspections for aluminum vessels in shipyards. Her expertise ensures compliance with class requirements and builds that hold up in extreme environments. From QA support on the SBX-1 to inspection of aluminum passenger vessels, Theresa plays a key role in helping EBDG deliver excellence in aluminum construction. Theresa provided Owner Representative services for much of the NYEDC fleet.
CONNOR BENNETT - MARINE ENGINEER
Connor supports aluminum vessel projects through structural design and hull optimization. His work emphasizes speed, performance, and safety in high-speed craft. By leveraging advanced modeling and data-driven analysis, he contributes to designs that meet mission requirements while maximizing fuel efficiency and weight savings. His involvement supports EBDG’s expanding work with fast ferries, utility boats, and other lightweight aluminum builds.
BEN FISHER, PE - NAVAL ARCHITECT
With over a decade of experience supporting aluminum vessel design and engineering, Ben contributes to aluminum projects through structural modeling, hull design, and performance optimization. With experience in both new construction and in-service support, he brings practical insight into stability, weight management, and transportability. His work includes designing trailerable aluminum craft and supporting quality assurance for passenger vessels, ensuring compliance with operational and regulatory standards.
ALUMINUM REPAIR EXPERTISE YOU CAN TRUST
Aluminum vessels demand specialized attention when it comes to repair and reinforcement. Whether the issue is structural damage, fatigue cracking, or corrosion-related deterioration, EBDG brings the technical precision and hands-on aluminum expertise required to restore vessel performance—safely and efficiently.
We support operators, shipyards, and owners with responsive solutions tailored to the unique challenges of aluminum construction. Our team includes marine aluminum structural experts and Certified Welding Inspectors (CWI) who understand the critical importance of aluminum integrity and minimizing vessel downtime.
OUR APPROACH TO ALUMINUM REPAIR
Repair of aluminum vessel structure is very different than steel repair work and successful repair requires EBDG use of our highly experienced aluminum structural staff. Our team has solved many complicated aluminum structural problems, including material failure and galvanic corrosion problems, to the satisfaction of the USCG, ABS and DNV.
Each repair project starts with a root cause analysis to ensure that the failure is addressed correctly and does not recur. Often the failures result from initial design or construction sequences. Major repairs have been necessitated by simple causes such as lack of limber holes in engine room stiffeners, poor isolation of dissimilar metals, design features that result in fatigue cracking, and incorrect weld sequencing. Often the solution requires more than just metal replacement. We engineer our repair procedures to prevent recurrence. When required we develop temporary repairs that allow the vessel to continue in service until the next scheduled maintenance period.
DEMONSTRATED SUCCESS
EBDG has delivered aluminum repair solutions across a variety of vessel types and challenging environments—from fast ferries on busy urban routes to vessels navigating harsh Arctic waters. We’ve successfully completed major aluminum repair projects, including extensive work on the AMHS high speed catamaran ferries Fairweather and Chenega, where our team led substantial engine replacement efforts. We routinely inspect and repair impact damage in aluminum hull structure and stress cracking in aluminum lifting gear. With a focus on practical engineering and operational performance, we ensure every repair meets the highest standards for safety, durability, and efficiency.
From concept through construction and repair, we bring deep expertise to every aluminum project. Our team of professionals understand the full lifecycle of aluminum vessels—ensuring every design is durable, efficient, and operationally effective. Whether you're planning a new build, adapting one of our proven designs, or extending the life of an existing vessel, we’re ready to support your mission—powered by the team at EBDG.
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