By: Andy Camarda
Paneled laminates offer an excellent balance of performance, durability, and affordability. These sails use pre-made, high-performance laminated materials that are computer-cut and assembled similarly to crosscut sails. Unlike composite sails, where fibers are custom-laid in-house, paneled laminates utilize off-the-shelf laminates engineered by specialized sailcloth manufacturers.
Construction & Materials
Laminated sail materials combine multiple layers to create a strong, lightweight structure with improved stretch resistance.
These layers typically include:
- Mylar film – Provides structural stability and prevents stretch.
- Load-bearing fibers – Typically Polyester, Carbon, Aramid (Technora or Twaron), or Dyneema, offering significantly less stretch than traditional woven polyester.
- Scrim (X-Ply) – A secondary fiber reinforcement in an X-pattern to help distribute loads.
- Outer Taffeta (optional) – A protective skin that adds durability:
- Woven taffeta – A traditional outer layer for improved longevity.
- Light Skin – A lighter finish using randomly arrayed polyester fibers, offering some protection without excess weight.
Most paneled laminates are built using a tri-radial panel layout, where fabric panels align with load paths to maintain shape and improve performance. Some laminates are available in crosscut layouts, though they are less common. These materials are laminated under heat and pressure by sailcloth manufacturers like Dimension-Polyant and Contender, ensuring consistency and high-quality construction.
Ideal Applications
Paneled laminates are a natural step up from woven sails, offering improved shape retention and reduced stretch. They are ideal for sailors looking for higher performance without the cost of fully customized composite sails.
Some common variations include:
- Cruising Laminates – Designed for durability and longevity (e.g., Contender CDX, Dimension-Polyant DCX, SXi).
- Racing Laminates – Built for lightweight performance and minimal stretch (e.g., DP Carbon Sport, GPL), often with an option for Light Skin or Mylar-only finishes.
Compared to woven sails, paneled laminates provide significantly better performance, particularly when using high-end materials. Their stretch resistance, shape retention, and customizable outer layers make them a great choice for both performance cruising and club racing.
Limitations & Considerations
While paneled laminates offer major advantages over woven sails, they do not have the fully customized fiber layouts of composite sails. This means they can be more susceptible to off-axis loads, such as when reefed, leading to localized distortions.
Other key considerations:
- Less flexibility in fiber orientation compared to membrane sails.
- Can be reinforced with multiple fabric weights, but lacks the infinite customization of composites.
- Over time, paneled laminates will stretch like all sails, but modern laminates have largely eliminated delamination issues. Instead, outer skins will gradually wear out with extended use.
Get in Touch
Interested in learning more about paneled laminate sail materials? Our team is here to help you choose the best sail for your needs. Explore our paneled laminate sails or request a quote today. For more information and insights on sail materials, visit our Learning Center.
