Efficient by Design: How Simonis Voogd Used Orca3D Marine CFD to Optimize Leopard Powercats

Overview 

In this Orca3D Customer Spotlight, we’re proud to feature the award-winning work of Simonis Voogd Design, whose latest Leopard Powercats, the Leopard 46PC and 40PC, represent a new generation of production cruising catamarans. 

Working in collaboration with production builder Robertson & Caine, Simonis Voogd led the design of these high-speed displacement catamarans with a mission: improve upon the already successful Leopard 51PC and 53PC models, while maintaining the same engine package and doing it all with smarter hull design and better efficiency. 

To achieve that, the team turned to Orca3D’s Marine CFD tools to optimize hull shape, fine-tune running trim, and predict performance with precision long before sea trials ever began. 

Project Goals & Background 

Leopard Power Catamarans are a familiar sight in marinas and charter fleets around the world. But with the 46PC and 40PC, Robertson & Caine wanted to push the envelope even further, delivering better fuel efficiency and handling without sacrificing speed or stability. 

Simonis Voogd’s challenge was clear: 

  • Improve performance across the full range using the same Yanmar engine package 
  • Meet CE Category A certification requirements 
  • Stick to proven production materials like E-glass/foam core and polyester resin 
  • To reach those goals, Orca3D Marine CFD would be a critical tool in their arsenal. 

Vessel Profile 

  • Vessel Type: Production Power Catamarans 
  • Design Studio: Simonis Voogd Design 
  • Builder: Robertson & Caine 
  • Length: Multiple sizes (40PC and 46PC) 
  • Hull Type: High-speed displacement catamarans 
  • Materials: E-glass, foam core, polyester resin 
  • Propulsion: Twin Yanmar diesel engines 
  • Special Feature: Propeller tunnel designed to reduce running trim and boost efficiency 
  • Certifications: CE Category A 

Using Orca3D: Predicting Performance with Confidence 

Orca3D played a central role in the design process especially when it came to optimizing the hydrodynamics of the hull. 

“Thanks to Orca’s CFD extension, we could optimize the craft and do accurate speed and fuel consumption predictions ahead of the trials.” 

— Alex Simonis, Naval Architect, Simonis Voogd Design 

Using Orca3D Marine CFD, the team was able to: 

  • Study the impact of hull modifications on running trim and resistance 
  • Evaluate prop tunnel design efficiency 
  • Compare theoretical predictions with actual trial results 
  • Achieve fuel consumption targets while improving performance 
  • This use of in-house CFD not only increased design confidence but saved valuable time and cost in the prototyping and testing phases. 

Challenges & Innovations 

One of the biggest constraints was material: to keep production cost-effective, the entire structure had to be designed using E-glass, foam core, and polyester resin only, with no exotic composites. 

This added weight and stiffness limitations, but Simonis Voogd was able to overcome them through careful hull shaping and by optimizing the trim and running efficiency using Orca3D CFD simulations. 

Project Timeline & Collaboration 

  • Design Period: 2022–2023 
  • Interior/Systems Design: Robertson & Caine in-house teams 
  • Naval Architecture & CFD: Simonis Voogd Design 
  • Support from Orca3D: Bruce Hays and Larry Leibman provided CFD setup guidance and best practices 

Results & Recognition 

The results speak for themselves: 

Beyond the accolades, the client saw a measurable performance boost achieved using the same engines as earlier models, but with a smarter, more efficient hull. 

“Orca3D made it possible to run accurate CFD work we could trust.” 

— Alex Simonis 

Final Thoughts 

Whether you're building a racing sailboat or a luxury power catamaran, getting performance right the first time is crucial. Simonis Voogd’s work on the Leopard Powercats shows just how powerful in-house CFD tools like Orca3D can be when used by designers who care deeply about efficiency, comfort, and real-world results. 

“I would highly recommend Orca3D for any designer or naval architect who wants to get into doing their CFD work in-house. As a whole, the Orca3D package is a valuable tool for any design from start to finish.” — Alex Simonis, Simonis Voogd Design 

Want to be featured in a future Customer Spotlight? 

Email support@orca3d.com with a short description of your project and how you’re using Orca3D. We’d love to share your story! 

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