Archive for the ‘New Sails’ Category

New sails give iconic Mari Cha III a burst of speed

Custom carbon Doyle Stratis ICE sails have been fitted to iconic yacht, Mari Cha III, delivering performance and speed. 

Mari Cha III has completed 5000 miles in just over a month of cruising with her new Doyle Stratis ICE sails, and her Captain Christian Lay has given us his take on how the new additions are performing under pressure.

The yacht was fitted with a full wardrobe of high performance ICE sails, created at Doyle Sails New Zealand’s Auckland loft, and the 44-metre yacht has been putting her new sail inventory through its paces. With the light, durable sails,Mari Cha III has found no loss of stability in arduous elements, delivering better performance and longevity.

“One of the big things we have noticed is how much easier the sails are to use than our previous ones. They set really easily and hold their shape so well,” says Lay.

“All the little details that we customised for this boat have made sail handling and manoeuvres, such as reefing, so much easier. The boat is very clearly faster. The service leading up to, getting hold of and then commissioning the sails cannot be faulted.”

Doyle Sails New Zealand’s Matt Bridge says the company enjoyed the process of producing the high-performance sails for the yacht.

“This was the first set of Doyle sails for Mari Cha III and working on such a well-known yacht was a really satisfying experience for us,” says Bridge, superyacht sails coordinator, Doyle Sails New Zealand.

“There was also a nice synergy for us, given that Doyle Sails New Zealand’s own Mike ‘Moose’ Sanderson, sailed onboard Mari Cha III during her record-breaking TransAtlantic crossing in 1998,” says Bridge.

ICE is a new generation UHMWP sail fibre first applied to the marine industry by the Doyle Stratis team, and tests have shown an exceptionally high resistance to flex fatigue, with ICE retaining its initial shape longer than other sail membranes.

“Dealing with the mizzen staysails and big code sails is now really easy and we can get rid of the 900 square meter code 0, in about 10 seconds, which allows us to sail the boat harder and more aggressively with a smaller crew,” says Lay.

“We have already done 5000 miles with them in a little over a month and had every configuration possible in winds up to 40 knots. There have been no issues with stretch, chafe or wear. We have pushed them downhill with boat speeds into the mid 20 knot region and then done big round ups in big breeze to get them down. The new batten system hasn’t broken one yet which is a big improvement for us.”

“In short I think it’s fair to say that we are pretty bloody happy with them and I am now thinking about which other sails we need to buy for the upcoming adventures. Oh – and for the first time – we have some decent sail bags that are strong enough, big enough, which have enough hand holds and look cool with the names on,” ends Lay.

Over 1 Ton of Sails | S/Y Ohana

Superyacht Ohana will feature over 1 ton of Doyle Sails

Superyacht Ohana will feature over 1 ton of Doyle Sails

Superyacht Ohana will have over 1 ton of Doyle sails on board.

Built by Fitzroy Yachts and designed by Dubois Naval Architects, Superyacht Ohana is a breathtaking 50-metre Flybridge Sloop, currently undergoing sea trials before her delivery in December.

With a total sail area of 4,085 m2 including her main sail of 636m2 and a gennaker of 1,600m2, Ohana will achieve a maximum speed of 18 knots under sail.

Superyacht Ohana will have over 1 ton of Doyle and Doyle Stratis on board. Ohana will be one to watch at the New Zealand Millennium Cup 2013 – the yacht’s first regatta.

See the photos below including the forklift used to lift the Mainsail and Staysail out of the loft and onto the delivery trailer.


LOA: 49.7m
LWL: 44.6m
Beam: 10m
Draught: 5.5m
Displacement: 370 tons
Rig: Southern Spars
Engine: Caterpillar C32 ACERT (1400 BHP)
Accommodation: Owners Cabin, 4 x Guest Cabin Aft, 1 x Guest Cabin Forward, 4 x Crew Cabins
Builder: Fitzroy Yachts
Naval Architecture: Dubois Naval Architects
Exterior Design: Dubois Naval Architects
Interior Design: Owner and Fitzroy Yachts
Sailmaker: Doyle Sailmakers New Zealand


Boat International: Sailing yacht Ohana begins sea trials Fitzroy Yachts launch 50m flybridge sloop ‘Ohana’ Fitzroy Yachts launches 50 metre flybridge sloop Ohana Dubois Naval Architects comments on recently launched Ohana
Dubois Design: Ohana launches from Fitzroy Yachts

Salperton IV Fitted with Doyle Stratis

Following the stepping of a new Southern Spar carbon rig, the 45 metre superyacht Salperton IV returned to Palma to have new Doyle Stratis high performance sails fitted.

With the order only placed in July 2011, it was a very tight schedule to complete the design and production of such a large project, but it was achieved with flying colors.

Following the sail trials, Doyle Palma Director, Quinten “Quinny” Houry said “The mainsail fits perfectly and looks and feels really fast. The Genoas have a great shape and will boost performance. The Stratis production system enables us to produce a quality performance sail that we expect to last longer than alternatives.”

Quinny was also very pleased with the success of the innovative furling batten system, a joint development between Doyle Sailmakers and Southern Spars, which works superbly. Small track cars are installed on the luff and these are able to furl around the boom, allowing the sail to be stowed, but still allowing for low friction cars on the mainsail luff.

The new sail program included mainsail, reacher, jib and purpose built racing blade genoa. This blade genoa was fitted with C-Tech air battens. These feature high pressure tubing along the leech. When connected to an air supply the batten pockets are pressurized. This system allows for fast sail changes without having to install, remove or store long battens.

What is the World’s Largest Main Made Of?

Doyle Stratis.

If you want the strongest, most reliable sails, choose Doyle Stratis. Mirabella V had her new Doyle Stratis mainsail fitted and trialed in St. Martin yesterday. Mirabella V is the largest sloop in the world: the single-masted vessel is 75-meters long (247 feet), and that mast also happens to be the world’s tallest, with the world’s largest main attached to it.

Mirabella V's New Doyle Stratis Main being lifted on the boat

The scale of Mirabella V’s sails required novel engineering, taking full advantage of Doyle’s extensive superyacht experience, from material development to novel construction techniques.

Mirabella V New Stratis Main
Mirabella V New Stratis Main

Mirabella V’s mainsail measures 1,200 square meters (12,900 square feet). Building and designing Stratis membranes for this sized boat facilitated the need for a new view on the engineering and safety margins. Tyler Doyle modeled the loads using Doyle’s combined CFD-FEA program and designed the structural load paths to best address the enormous loads that this boat will generate. The Stratis main was built in Doyle’s custom built 32,000 square foot superyacht manufacuring facilty in Salem, MA.

Mirabella V Segmented Mainsail

In 2004, when Mirabella was first launched, Doyle invented the “Segmented Mainsail” and “Compression Spring Battens” to allow a sail of Mirabella’s size and complexity to be manufactured, handled and serviced efficiently. With the "Segmented Mainsail" design, the new Stratis mainsail is composed of three separate, yet interdependent, sections. Two full-length battens join the segments at the top and bottom edges to form the complete sail. Building the sail in these segments makes construction, transport and service significantly easier.

Mirabella V Compression Spring BattenThe batten development for Mirabella V was largely a question of optimization: at the required batten stiffness, what is the maximum toughness that could be achieved while minimizing weight aloft? The "Compression Spring Battens" clearly demonstrate Doyle Sailmakers’ commitment to durability and toughness.

Just a year ago Kokomo III was outfitted with 3,038 square meters (32,700 square feet) of Doyle Stratis. Her Gennaker at 2,227 square meters (23,971 square feet) is the largest sail ever constructed. To read more about Kokomo, click here.


Kokomo Sets Sail with 3,038 Square Meters of Doyle Stratis

Kokomo III Sets Sail with 3,038 Square Meters of Doyle Stratis

Kokomo – the 3rd in a series of Dubois designed Superyachts for the same owner – had her sails fitted and trialed on the Auckland Harbor over the last week by Doyle New Zealand. She hosts a complete inventory of Doyle Stratis membranes designed and produced in New Zealand, and easily boasts many records in sail construction and sizing world wide. At 2,227 square meters (23,971 square feet) the Gennaker is thought to be the largest sail ever constructed. The working inventory comprises of a total of 3,038 square meters (32,688 square feet) of Stratis membrane sails, and many innovations in sail handling systems and detailing. The Mainsail has a custom designed boom furling system that utilizes the conventional bolt rope system of the Southern Spars, but also a self loading batten car system jointly designed and tested by Doyle and Southern Spars over the last 18 months, which addresses many of the weak points of boom furling systems with the advantages of full battens in a yacht of this size.

Building and designing Stratis membranes for this sized boat facilitated the need for a new view on the engineering and safety margins along with a new custom built 6,500 square meters Stratis lamination facility in Auckland. Over the period of 12 months Richard Bouzaid and Peter Heppel utilized the fabric structural design program Relax 2 to accurately model potential loads and redesign the previously used structural load paths to better address the enormous loads that this boat will generate. The investment and lessons learned from this new generation of Superyacht places Doyle well and truly at the leading edge of this market and the future of these high performance luxury yachts.

Kokomo III: 3,000 Square Meters of Doyle Stratis

Doyle Sailmakers will be delivering the latest 58.4-meter Kokomo with the largest Stratis sails to date. The new Alloy Yacht designed by Dubois Naval Architects is fitted with the world’s 2nd biggest carbon fiber mast at 75 meters tall. Doyle Sails New Zealand is fitting Kokomo with 3,000 square meters of Stratis sails.

Doyle Sailmakers have become one of the leading manufacturers of superyachts sails with 4 of the 5 finalists in this year’s Superyacht awards sporting Doyle STRATIS™ sails. Doyle Sails head designer Richard Bouzaid explains the process for developing a STRATIS™ sail for a Superyacht, from the sail design and fit to the boat, through the engineering and manufacture of the STRATIS™ membrane at the 21,000 square foot temperature and humidity controlled plant in Auckland New Zealand.

As with any sail, the first stage in the process is the sizing of the sail. This is especially important on large yachts as errors are costly and often require cranes or the like to take sails on and off a yacht. Accurate measurements are required of all the parameters of the boat to ensure that this process is done correctly. Our first stage in the process is to build an accurate 3D model of the yacht within our design software. These models are accurate to millimeters and include all of the relevant detailing that can effect the fit and performance of the sail. The model shown below is the new 58 meter Dubois designed Kokomo.


These models include all details of the sail attachment points, furling units, head swivels, mast detail with halyard positions, spreaders and other potential conflicts with the sail such as communication equipment, genoa cars in potential positions, stanchions etc. This allows us to then fit a sail to the model and know with certainty that the sail will not only fit correctly to the 3 attachment points, namely head, tack and clew, but also where and if the sail will have other stress or chafe points due to fittings on the boat. They can then be suitably reinforced or the geometry altered to avoid this conflict. The accuracy of this type of modeling has been one of the biggest steps forward with sail design software in the last 10 years.

Shape optimization is the next stage in the sail design process. Base sail shape molds are used for certain geometries and applications and then adjusted for the requirements of the actual sail that is being designed, for example a cruising genoa will have more shape in the back to be more effective when the sheet is eased. During this process the sails will be accurately aligned to the actual attachment points so that mastbend and headstay sags can be incorporated into the sail design. Loadpath (custom fiber laid sails) as a sail is engineered to stretch a certain amount, rather than to a % of its ultimate breaking strength. For a high performing sail we would be typically looking for a maximum elongation anywhere in the membrane in the region of 0.15-0.2% and it is important that the elongation (stretch) is as uniform as possible in the membrane in all areas of use. This dictates how much fiber is required in any area of the sail. The graphic shows the stretch through the sail and where the sail has more stretch than the desired amount, shown green.

During this process of establishing the correct fiber alignment and density, different combination of fibers may be used to get the best balance between weight and overall durability. There are various fibers that we use in a STRATIS™ sail depending on the application. Performance cruising boats will typically use Vectran or a combination between Vectran and carbon fiber. Performance racing boats will use twaron (Kevlar), Carbon fiber or a combination of twaron and Carbon fiber.

Once the orientation of the fibers and the density has been finalized the fiber map for the sail will be programmed into the 12m wide x-y plotters that will lay these fibers onto the surface that will become one of the sides of the finished sail. These fibers are all laid under tension to exact paths determined by the earlier studies.

The final process in the membrane manufacture is the application of the top surface.This is also a film sheet, often with a polyester taffeta on the outside, and pre coated with glue. This is finally vacuum bagged to the table and the laminator, which uses infrared heat lamps and 12000KG of downward pressure. The laminator will then make computer controlled passes over the membrane to activate the glue and expel and remaining air in the laminate. The factory has 2 of this style of laminator operating. The membrane is left to cure for several days before being moved to the Doyle New Zealand 30,000 square foot sail loft floor for finishing, or shipping to one of the many Doyle Lofts worldwide for completion.

InMocean with Innovation

Doyle Superyacht InMocean

InMocean, the latest Dubois Designed Sloop from Fitzroy yachts, is seen here sailing in the Hauraki Gulf. InMocean has some of the latest thinking from Doyle Sailmakers incorporated into her sails. The UV strips are the new Painted UV solution exclusive to Doyle Sailmakers, and she has her logo embeded in the Mainsail and Genoa laminates using Carbon Fibers giving the effect of a water mark.


Doyle Superyacht Bristolian

The Briand designed 120′ sloop Bristolian sails with her new Stratis sails by Doyle.

Red Dragon

Doyle Superyacht Red DragonDoyle Sailmakers has launched into the new year with one of the largest projects to come from the Stratis manufacturing facility in New Zealand.

The 52m Red Dragon, the latest Dubois Superyacht from Alloy Yachts, had sails fitted and commissioned in January, marking a milestone for Stratis – by far the largest sails produced to date, and by all accounts probably the largest custom inlaid fiber sails produced by anyone in the world.

Since Doyle New Zealand embarked on the Stratis project over five years ago in conjunction with Technology New Zealand, Doyle New Zealand has produced over 2,000 racing and cruising sails. Stratis sails have been exported to almost every country with Doyle Sailmakers locations worldwide purchasing the sails in either completed form or as a blank sail membrane to be finished with their own personal touch.

The total Stratis membranes on board Red Dragon account for over 27,000 square feet of sail area – an impressive feat by anyone’s standards, with the reacher alone coming in at just over 8,500 square feet. New Zealand innovation products are always at the forefront of the marine industry, and the Stratis Membrane Sails from Doyle New Zealand are being selected by a very high percentage of the new and existing Superyachts being produced due to the weight savings, performance increases and benefits of a sail that can be specifically engineered to address the exact load path on each corner of the sail. Every specific fiber sandwiched between the polyester or mylar laminates is engineered from propriety software and then mapped to a fully automated manufacturing process. Various fibers such as vectran, carbon fiber and kevlar are selected dependant on the owner’s requirements.

Super Maxi Maximus also selected exclusively GPx Stratis Membrane sails for their bid to compete in the 2007 Sydney to Hobart race, but unfortunately Maximus had to withdraw prior to the race start with keel problems.

Join the revolution and contact your local Doyle Superyacht Loft to discuss the right Stratis sail for your boat.

Douce France

Doyle Superyacht Douce FranceDouce France, a 42m Catamaran, reputed to be the largest in the world has just completed sea trials supporting a new set of Doyle Stratis GPc sails. The yacht has just completed an extensive refit at New Zealand Yachts in Whangerei and is now continuing on her extensive charter season in the South Pacific.