Modern sailmaking

By Christian Brewer British Sailing Team Member and Former Olympian

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A look into the future of sail manufacturing

Sailmaking is almost unrecognisable from 50 years ago, when sail lofts were common place throughout the coastal towns of the UK. Each sail was hand crafted in canvas or early synthetic fibres, often by generations old family businesses. These days, modern laminates, once deemed unsuitable for ocean sailing, now grace racing monohulls and trimarans. In this article I explore the future of sailmaking through the lens of cutting edge materials, digital design, global manufacturing and the enduring role of independent Sailmakers. Let’s take a look at the advancement in technology, manufacture and the future for sailmaking.

Materials

Woven fabrics

These are still the benchmark for cruising and budget sailing. Thanks to advanced weaving and finishing processes, today’s sails hold their shape for longer and are more durable.

One challenge, however, is sustainability, with old sails being notoriously difficult to recycle. Some 2,000 tonnes of sail cloth is discarded each year, most of which is non recylable due to its high plastic content. Fortunately, investment is well underway into finding a solution to break down old sail cloth into its chemical component building blocks using green and bio technology, without extensive use of harsh chemicals.

North Sails is leading the way with its NPL RENEW range of cloth which boasts 90% sustainable material content. Although not made from recycled sail material yet, but they are working towards that goal.

Laminates and membrane sails

Usually found on larger cruising (over 45ft), and racing yachts. The benefits are less stretch and lighter weight compared to woven material. Developments in sail lay ups see continuous fibre strands laid across the load paths on the sail on a 3D mould, these modern techniques see a further weight reduction with increased strength. These sails are lighter, stronger, and more reliable than ever.

New designs also rely less on mylar film to carry the fibres, which show a tendency to delaminate over time.

Close-up of a sewing machine stitching black fabric, guided by hand—like following a Guide to Poole for precision.

Person in a green shirt measures fabric on the floor, possibly crafting a sail for a Guide to Poole adventure.

Design

Computer-aided design

The biggest changes have come about through computer aided design software. These modern design tools allow precise modelling of the fibre alignment and fibre type, giving much improved strength to weight ratio. Today’s top Sailmakers use new load cell technology in the design process, giving real time data when out sailing.

Durability built in

Reliability in laminate construction has changed dramatically as we see from the IMOCA class, taking on the world with just 8 sails in their wardrobe. The finisher’s sails looked to be in great shape even after up to 99 days at sea, and in the worst sailing conditions on the planet. Sails are designed to the class rules, with input from each team determining the final shaping and material choices with their chosen Sailmaker.

Manufacture

The cost and complexity of manufacturing these technologically advanced sails has led to centralised production by the world’s leading Sailmakers, predominantly in the Far East.

Gone are the days when numerous individual sailmaking facilities would be dotted around each country, sharing design data and branding. This is now centralised with designs sent to the main manufacturing plant where the sails are manufactured and delivered complete or in panel form for assembly locally.

Nations such as the Philippines, Sri Lanka and China, each with political stability and highly skilled textile work forces now host the production sites of the world’s largest brands. Global shipping networks are now so advanced, customers can receive finished goods within days rather than the weeks it once took.

Person sewing blue and white fabric with a sewing machine, viewed from above—a glimpse into modern sailmaking.

Independent Sailmakers

There will still be a good demand for independent Sailmakers who can offer the kind of personal, trusted service that the larger brands can’t. They also often branch into other areas of cloth structures such as awnings and sunshades. Many of these businesses have been passed down in the family, from generation to generation.

Their advantage is that they can match their customer requirements exactly, be that measuring the boat, fitting the sails and sailing with the customer. They can also offer a winter service with repairs being carried out to prolong the life of customers’ sails.

Independents can increase their turnover without increasing their own capacity by using a private label build service such as that offered by Durtek, based in Sri Lanka. The Sailmaker can input their own designs and specifications and receive a high quality dacron or laminate sail which can be benched and completed in house.

In summary

Sailmaking is heading in two clear directions: mass production powered by global logistics and advanced composites, and bespoke service rooted in traditional values and customer care. There will always be room for the independent sailmakers who have the advantage of reacting quickly to demand and offering a great service.

With sustainability efforts gaining momentum and technologies evolving rapidly, we will also see more developments in the recycling of sail material.

So, whether you’re racing offshore or enjoying peaceful coastal cruising, one thing is clear – today’s sails are more advanced, more durable, and more eco-conscious than ever before.

Man in red sailing gear steers a small sailboat—Guide to Poole’s vibrant lakeside sailing scene.

Christian Brewer is a member of Whitstable Yacht Club and a former Olympic Squad and British Sailing Team member in the Tornado class.

He has won fifteen National and one European Championship in catamarans and in One Design keel boats.

A former sailmaker and charter yacht sales manager, Christian has sailed extensively in Europe, the Caribbean, Pacific, Atlantic and Indian Oceans.

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