Maxx Laminates

Contender Sailcloth has just introduced an intriguing new line of asymmetrical laminates they are calling Maxx (for Multi-Axial). These laminates are specifically designed for use in a sophisticated version of the classic cross-cut panel arrangement.

Typically, laminates are very much better at resisting stretch in the warp and fill directions than on the bias, that is, off the primary thread line directions. Ever since the 1980's, laminates have been optimized for use in radial panel arrangements. This allowed the warp strength of the fabric to be closely aligned with the loads in the sail.

There are two primary problems with radial panel arrangements. First, they are not terribly efficient at using fabric or labor. A typical radial sail will involve about 15% material waste, while a cross-cut sail waste is typically 5-7%. Moreover, a radial sail may have 40-50 pieces, while the same size crosscut sail might have 15-20.

The second problem with radial sails is that the shaping is more difficult. Sails are shaped by adding curvature to the edge of a panel where joins its neighboring panel. If that seam is parallel to the load it is more difficult for the curvature to spread itself across the panel than if the seam is perpendicular to the load. Radial sails by their very nature have most of their seams parallel to the loads.

The problem with crosscut sails has been the difference in stretch on the fill and bias, especially near the corners of the sail. The Maxx laminates address this problem with three axes of fiber orientation at 90° (Fill direction), 82°and 70° to the panel direction, but the non-fill fibers only lean in one direction (thus the asymmetry). Thus, fabric for the head and tack will be upside down compared to fabric for the clew.

This fabric has another nice characteristic compared to most laminates: it has a very soft flexible feel. This may reduce the film shrinkage that dogs most laminates.

We expect to be building our first sails from Maxx laminates for the 2004 season. We'll report back when we have more information.