Did you ever wonder how your sail is made? Let us run you through the process so we can help you understand the journey your sail goes through before it reaches your boat.
Sail Design – Nesting – Cutting – Seaming – Broadseaming – Stitching – Tapes and Reinforcement - UV Hemming and Stitching – Finishing – Customisation – QC and Measuring - Cleaning – Packing – Shipping
Sail Design We have a huge array of sail designs on file for the vast majority of “standard” boats. Our software allows us to save rig data on each of these boats to ensure our sails will fit perfectly. During the design process we’ll ask you a few questions to make sure that our data will fit with your boat. If we need to double check anything we may ask you to take some simple measurements or we’ll send you some dimensions which you can quickly confirm will work for your boat.
Nesting Once Design is complete we will separate each panel and patch and use a nesting software to carefully control the orientation of the panels to ensure they are aligned correctly with the fibres in the sailcloth for optimal performance and strength.
Cutting When the nesting is complete this information is sent to our Computer controlled cutting table which accurate cuts the sailcloth as well as marking the panel numbers and the position of seams, draft stripes, batten, windows and other features on the panels. Our cutting staff will also inspect the cloth before cutting to make sure no defects will be present in the cut panels and patches.
Seaming After cutting we assemble the parts like a giant jigsaw puzzle an seam them together using a specialised tape in preparation for stitching.
Broadseaming
Once the seams have been stuck we will begin to assemble the sail by stitching the broadseams and or panels together. Using a triple zig zag stitching machine for maximum strength on these major joins.
Stitching
After the broadseams are complete we will go about stitching the rest of the sail including the patches, additional panels, belts and reefs on pu