Paneled Sails

Paneled sails

As an alternative to the 4T FORTE™, M3™ and Vektor2™ continuous yarn options and VantageOne™ glued membranes, OneSails offers more traditional woven cross-cut and tri-radial paneled sails.

The cross cut or horizontal panels is the way to build simple and robust sails. Even today, fabrics are still very popular because they are durable and inexpensive. Sails in Cross Cut are also the most cost-effective to manufacture.

In short, a fabric consists of long warp and short weft threads, which are interwoven at 90 ° angle. To offset diagonal loads, sailcloth manufacturers have come up with some ideas. One is called "heat setting", where the polyester fibers are shrunk by heat after weaving. The fabric becomes more compact and gains diagonal stability. Another is resin coating: resin fills the gaps between the weave yarns and, as long as the coating stays on it, adds diagonal ("bias") strength to the material.

They also use different yarns for the warp and the weft, to suit different applications: namely, on high aspect ratio (tall and narrow) sails, the weft (also called "fill") yarns are stronger, as the higher loads on the sail are mainly vertical.

OneSails fabrics:
The cross cut or horizontal panels is the way to build simple and durable sails, however, loads outside the yarn directions of the fabric aren't directly offset by the material. Therefore, the quality of the cloth used is crucial for the life of the sail.

OneSails offers two types of crosscut Dacron sails, both made from high quality Dimension Polyant fabrics: Dacron HQ, recommended for offshore or intense use, and Dacron premium for other uses. In any case, it is important to have a premium quality weaving for a maximum high diagonal stability..

Suitable for: sails up to about 35 square meters with acceptable performance.

The radial cut makes possible to produce sails that are lighter and more dimensionally stable than Cross Cut ones.

Warp oriented fabrics.

In the radial panels, the cloth yarns and the seams are oriented along the load path lines of the sail and the warp yarns are taking most of the strain. The requirements of fabrics suitable for the radial cut are different from those used in traditional crosscut.

Recently, cloth manufacturers have developed a new special weave which greatly reduces the initial stretch caused by the yarn crimp, typical of "strong warp" sailcloth.This fabric is offered by Dimension Polyant under the name of Pro Radial (PR). It is suitable for all sails (except of course gennakers and spinnakers) and achieves a very long service life.

Mixed yarn fabrics

Hybrid fabrics in which polyester fibers are interwoven with high modulus polyethylene (UHMWPE) have the longest life among sail materials. Hybrid fabrics however cannot shrink evenly when heat set, so, for better diagonal stability, yarns are mechanically roughened before weaving and receiving the resin coating. The special weave of Dimension/Polyant's HydraNet Radial (HNR) has been developed for radial application.


Laminates are sail materials where the structural yarns are encapsulated between two films. These films are mostly made of polyester, with DuPont's "Mylar" being the universally known one. Films can also be coupled with a so-called taffeta (light polyester) fabric from the outside for a longer service life. Sometimes this takes the form on a non-woven cloth, called by Dimension/Polyant "Liteskin" .The external taffeta fabric works as a shield and provides better abrasion protection.

The way laminates are built makes it heavier compared to woven fabrics, on whose they have the advantage of a greater bias stability provided by the films. The structural yarns can be made from different fibers. For cruising sails polyester or polyethylene make the most sense because they don't suffer of carbon's fragility and aramid UV sensitiveness.

OneSails fabrics:
OneSails recommends fabric for the production of triradial sails, which have been specially developed for this cut. HydraNet Radial, polyester/UHMWPE hybrid, has been on the market for 20 years and has more than proven itself for high mileage cruisers. It is the first choice for circumnavigators and those who expect the maximum life from their sails. Alternatively, we use ProRadial, which is 100% polyester and has a similar special weave.

Suitable for: cruisers looking for a good compromise of long lasting and shape holding.

For efficient shape holding sails, the structural yarns consistently follow in curved lines the force distribution in the sail. The fiber layout is custom designed for each sail.

OneSails membranes:
In the development of new manufacturing techniques for high-tech sails, two fundamentally different philosophies have been followed. The two main families are membranes laminated in 3D with continuous yarns (the so called one-piece sails), while the others are made of individually laminated flat panels with horizontal joining seams. OneSails offers a wide range of advanced membranes made with both the technologies: 4T FORTE™, M3™ and Vektor2™ are continuous yarns while Vantage One™ is paneled. They all are suitable for all kind of sails which can cruise many miles in the best shape.

Continuous yarns (a) - Paneled (b)

Suitable for: cruisers and racers looking for light and handy sails with the best performances.