This construction starts with cross-cut panels using one of the newer laminates that have been designed just for cross-cut sails. The sail is assembled using a laminate that is lighter than is needed for a pure cross-cut sail, and then the LoadPath yarns are laminated on top of it to provide the strength needed in different areas of the sail.
The advantages of this type of sail are that it is lighter than a cross-cut sail, has continuous yarns running from corner-to-corner and corner-to-edge to fully support the membrane and take care of all seam loading, and is much more cost effective than either a tri-radial or pure-string sail. They are slightly heavier than the pure string sails because of the extra layer of Mylar that the load path yarns are laminated with, but are coming in about the same weight as a tri-radial sail.
The “Performance” line is constructed starting with base materials of Polyester, Pentex or Aramid, followed by continuous, hand-laminated yards of Pentex, Spectra, Kevlar or “S” Glass are applied in the load mapping of the sail. This option achieves a very good combination of weight, performance, durability and price.
The “Extreme” line represents the Grand Prix racing approach. These sails begin with base materials of Technora, Kevlar or Spectra, then continuous yards of Carbon Fiber, Spectra, Technora or Kevlar are laminated to follow computer-generated load maps. These sails offer the best combinations of weight, performance, strength and durability, with prices about 10 percent less than carbon tri-radial cut sails.
“Offshore” LoadPath sails are designed and engineered for the offshore cruisers and racers. These sails begin with Spectra cloth with a single side of Taffeta. Next, continuous fibers of Carbon Fiber, Spectra and Technora are hand laminated to follow loads from the corners, reefs and along each side.
Carbon and Aramid Fiber LoadPath
These sails are the ultimate in state of the art, LoadPath sail construction. Used in combination with proven laminate materials acting as a base or membrane, strings are laminated externally in a straight grid pattern that form an immovable structure that locks in the desired flying shape. These sails benefit from being created from what is the world’s only true three-dimensional sail design software. This software is universally regarded as the world’s most advanced sail design software and used by every Americas Cup syndicate. Panels and parts are cut from tested materials on a high-speed CNC cutter, which is accurate to within a thousandths of an inch. A carbon multi-fiber headsail is constructed with carbon fiber strings oriented to utilize a modern variable direction load path pattern. Carbon fiber is light weight, strong and impervious to sunlight. Carbon has also demonstrated exceptional performance and longevity in the offshore arena. Carbon multi-fiber headsails arrive complete with sail numbers, draft stripes and sail bag. Other features are added when appropriate.
Multi-Fiber Aramid LoadPath
These headsails utilizes a LoadPath technology that maximizes a sail’s fiber to strength ratio like no other type of sail construction can. These mainsails are constructed with Twaron or Kevlar strings oriented to utilize the latest in variable-direction load path patterns. The base materials are laminated goods from one of the major sail cloth manufacturers, thus guaranteeing the highest quality and proper lamination. The structural fibers run continuously across the sail from corner-to-corner and corner to edges over laying all seams. This technique eliminates seams as a structural component and any possibility of shape movement or seam failure. The base sail arrives standard with sail numbers, draft stripes, modern elliptical corner reinforcements, stainless steel rings, leech and foot lines, telltales and a sail bag. Other features added standard when appropriate.