Tekad Marine, in Turkey, did a good job of laminating a rugged, well-engineered hull. Vinylester resin was used for the outer skin coats, and a schedule of E-glass stitched roving and mat constitutes the laminate on either side of one-inch ATC Core-Cell AL-500 foam-sandwich material. The Expedition 55 was built on a male jig rather than in a female mold. Computer-generated station templates were used to define the transverse shape of the hull and deck, and these were set up on a center-line strongback, with battens slotted in place defining the hull's contours. The foam core was secured to the jig, and the outer layers of fiberglass were laminated over the core. Once cured, the vessel was rolled right-side up, the jig removed, and the inside hull skin applied. The core was cut out in high-load areas and in-filled with extra layers of glass laminate. The deck was built in a similar fashion, with solid-fiberglass backing plates used where appropriate. Once fully cured, a combination of bonding and mechanical fastening joined the hull and deck. Fiberglass tanks were built into the hull, and a stick-built approach to the custom interior made good use of the shipwright's carpenters.