Sails: Tyra Ply, the revolution from the roll. DP launches new sail laminate without film

Products such as 3Di from North Sails or 4T FORTE from One Sails have shown the way: laminates without Mylar foil, also known as film, are lighter, stronger and usually more durable than conventional laminates. Until now, however, this technology has only been available in the high-end sector with corresponding prices. This is set to change with Tyra Ply. Unlike membrane sails, Tyra Ply, like classic laminates, is produced in rolls and processed by the sailmaker into a radially or horizontally cut sail. The material is based on fibre bundles, known as tapes, which are laid side by side and glued together by a machine. In a second work step, a robot arm lays further fibre strands on top. The trick here is that the robot can lay the filaments in different directions, which means that the fabric can also absorb loads that deviate from the main orientation of the fibres.

The direct bonding of the fibres is said to be at least as durable as conventional laminates, and even has clear advantages when joining the panels in the sail. The adhesives commonly used there penetrate the filament structure, making the bond more stable than the surrounding material. Another advantage relates to water absorption. With conventional laminates, moisture can penetrate through pinholes and spread along the fibres. This problem does not exist with filament sails.

Enormous range of applications

At the start of production, Tyra Ply will be made from aramid. In principle, however, almost all high-strength fibres are possible. "We can process aramid, UHMWPE fibres such as Dyneema, Vectran and carbon as well as combinations of these. The limiting factor is the availability of the filaments," says Dimension Polyant Managing Director Uwe Stein. According to him, it is currently almost impossible to obtain the required quantities of Technora or Vectran.

The large selection of fibres and the variable filament density result in a wide range of applications. According to Stein, it ranges from wings for wing foils to dinghy and tall ship sails to applications in boat building. "With fibre densities of up to 20,000 dpi, we cover sails for yachts up to around 60 feet," says Stein. The material covers different target groups. In addition to the performance-orientated performance cruisers, cruising catamarans also come into question. Stein explains: "They are getting heavier and heavier, which also requires more stable sails. Conventional laminates or even fabrics can hardly be traded in the required material thicknesses".

As with conventional sails, the UV protection required for aramid and Vectran fibres is provided by a coating of Liteskin or Tafetta, meaning that the service life of Tyra Ply should at least match that of Mylar laminates. In terms of price, Dimension-Polyant classifies the material between the BX and GPL laminates.