By: Andy Camarda
Overview
Designed from the fiber up, EM2 Composite Sails are lighter, stronger, and more precisely engineered than traditional paneled sails. Built entirely from the ground up, these sails deliver unmatched performance, control, and durability. Backed by our state-of-the-art, fully integrated in-house manufacturing process, every EM2 sail is designed, engineered, and produced with rigorous quality control and advanced computer-aided design, ensuring exceptional consistency and reliability.
Materials and Construction
Unlike traditional sails that rely on off-the-shelf materials, EM2 Composite Sails are completely custom built. Designers have the freedom to precisely position load-bearing fibers—using high-performance materials such as carbon, aramid fibers (including Twaron, Technora, and Kevlar), and, for larger boats, Vectran—without the limitations of a premade panel layout. This highly tailored internal matrix not only creates an exceptionally strong sail but also significantly reduces weight compared to conventional paneled designs.
A wide array of outer skins is available to meet specific performance requirements:
E-Tech
Ideal for light air and inshore sails, offering a light and robust finish.
Element
Our versatile skin for club racers, offshore racers, and racer cruisers, available in three weights to deliver the perfect balance of performance and durability.
Expedition Woven Taffetas
Designed for extreme durability, these skins excel under the rigorous demands of long-distance and offshore sailing, even making their mark in high-performance racing inventories.
Innovative Manufacturing Process
At our expanded membrane plant in New Zealand—built in 2022 and one of the newest and most advanced facilities in the world—we combine cutting-edge production techniques with continuous research and development to produce every EM2 Composite Sail. Our advanced process ensures every EM2 sail is built with perfect fiber alignment, precise lamination, and unmatched durability, giving sailors confidence in both performance and longevity.
While often referred to as “membrane sails,” our EM2 Composite Sails go beyond traditional membranes, eliminating past delamination concerns with superior materials and construction techniques.
This integrated process allows us to rapidly iterate designs while maintaining strict quality standards, ensuring that each sail meets the demands of both high-performance racers and dedicated cruisers.
Advanced Reinforcement and Performance
EM2 Composite Sails benefit from a sophisticated internal matrix and strategically targeted reinforcements. Custom enhancements are applied around critical areas—such as corners and reef patches—to ensure structural integrity. Additional reinforcements target secondary load points—including reef tie-down points, battens, and luff attachments—to prevent distortion from off-axis forces. Batten pockets are integrated internally, utilizing the sail’s outer skin for extra strength, which reduces the risk of failure and minimizes maintenance. For ocean and offshore finishes, extra layers of internal reinforcement support spreader patches and edge tapes, reducing distortions from spreader strikes and leech flutter to ensure peak performance over time.
Ideal Applications
EM2 Composite Sails are the top choice for sailors demanding the ultimate in performance, control, and durability. They are ideally suited for:
- Racing: Whether you’re a club racer or an offshore competitor, these sails offer precise control and significant weight savings. With superior shape retention, EM2 Composite Sails stay fast longer, reducing drag, increasing efficiency, and extending the life of your sail—meaning fewer replacements and more time sailing at peak performance.
- Cruising: For sailors seeking enhanced performance and superior control in mixed wind conditions, EM2 Composite Sails deliver improved handling and responsiveness. Unlike traditional sails that may lose shape and create drag or excess heel, these sails offer the best shape retention we provide—translating to a smoother, more controlled ride.
Get in Touch
Ready to upgrade your sailing experience? Explore our EM2 Composite Sails and find the perfect fit for your needs. Create your custom sail online or request a quote today. For more information and insightful articles on sails and sailing, visit our Learning Center.
The combination of a custom interior matrix, advanced internal reinforcement, and our innovative in-house manufacturing process allows our designers to create the perfect sail for any application—ensuring that whether you’re after a light inshore sail or a high-performance cruiser, EM2 Composite Sails deliver excellence on every voyage.
