Stratis Manufacturing Process

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Fiber paths are applied 3 dimensionally to custom load calculations for every sail. Doyle's in house load and fiber distribution program is applied to calculate load paths. With extensive experience in both Grand-Prix and Superyacht markets, Doyle's team of engineers and designers have the tools to carefully review the specific loads within the membrane, to ensure that the correct amount of fibers are laid in every area of the sail. The end result - a smooth preshaped Stratis™ sail is fitted to the boat.


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The step of mapping the yarns from the design process to applying fiber to the base laminate is exact. A fully automated fiber bed allows for up to 18 yarns in each pass - faster than a conventional paneled sail can be cut out. Once the orientation and density of the fibers has been finalized, the fiber map for the sail will be programmed into the 12m wide x-y plotters that will lay the fibers onto the surface. This base surface 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 individual fibers are pre-impregnated before lamination, to ensure accurate weight calculations and optimized lamination. Additional yarns can be run in areas of impact, as well as around battens and reefs. Compression yarns can be run around the highest load areas of the sail to ensure that the sail maintains its optimal flying shape as the sails loads up.

Lamination & Consolidation

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The final process in the membrane manufacture is the application of the top surface. This top surface is also a film sheet, often pre-coated with a polyester taffeta on the outside. This outer surface will typically integrate an additional X-Ply to address off axis loading and ensure durability in the sail.

The laminated membrane is finally vacuum bagged to the table and then the laminator, using infrared heat lamps and 12,000kg of downward pressure makes computer controlled passes over the membrane to activate the glue and expel any remaining air in the laminate. The STRATIS™ factory operates with two of these laminators.

This step is essential to ensuring the long-term durability of the Stratis membranes. Custom adhesives developed specifically for Doyle Sailmakers resist moisture absorption, while UV inhibitors within the glue protect the laminate from UV degradation. The humidity and temperature is strictly regulated within the lamination facility to reduce atmospheric moisture within the laminate.


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All of our trained sail technicians have practical on the water experience, combined with finishing techniques that come from years of experience.


Red Dragon

The reality of the finished product is a sail precisely fitted to the yacht - Ultimately a smoother, faster and significantly lighter sail. Stratis sails offer the cruising and racing sailor a like the perfect product every time.

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