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3DL CHARACTERISTICS

L a m i n a t i o n

Most efficient stru c t u re .

The multiphase polymer that bonds the 3DL laminate, developed by North Sails R&D staff, isan example of the technological strength used in 3DL manufacturing. The 3DL adhesive blends two distinct polymers that cure at different rates when heated.The results is excellent endurance of the laminate and a strong bond between yarns and filmthat coats only the surface of individual yarns and yarn bundles. This allows microscopic movement of fibers within yarn bundles thus increasing the sail's inherent flexibility. This flexibility means a 3DL sail will pass around the mast more easily during tacks and assume its flying shape more quickly. O t h e r : interrupted yarn paths on 2-D shape

The continuous yarn stru c t u re

> > Built in onep i e c e
3DL is manufactured as a unitary membrane on full-sized 3-dimensional molds.This is a revolutionary sailmaking technology. 3DL structural yarns are applied in the exact shape they will assume when sailing, the yarns run uninterrupted along load paths: the 3DL could harnesses the wind power more efficiently thanany other sail. 3DL yarns structure > > T h e rm o - m o l d e d
RM mach i n e 3DL: > > No seams to i n t e rf e re with load transition
continuous yarn paths on 3-D shape Effective wind range.

The added dimension

The greater wind range of each 3DL sail means less sail changes and a smallernumber of sails in the inventory. Only 3DL is molded 3-dimensionally with structural yarns (red)running uninterrupted along load path

New technologies: 3DL RM

3 DL sails could be built using different technologies, that share thesame high-levels of innovation and the same high-quality .The new Rota ry Molded technology is a futuristic cylindricalstructure in which film and yarns are disposed in a revolvingand heated drum. The drum surface, made by flexible material, can assumethe designed 3-D shape created by sail-designer.The process begins and ends at each single rota t i o n ,and allows short throughput times. The 3DL RM process is suitable for small boat sails.

Consolidation of the laminate

Vi rtual Wind Tunnel (VWT) > > 3-dimensional flying shape
The 3DL laminate is thermo-formed by heating and by using one atmosphere of vacuumpressure of about 2400 kg/mq.The vacuum pressure (in combination with heat) sucks the film down tightly around the yarnsusing uniform bonding pressure in all directions. This is called "consolidating the laminate"because it results in a laminate of solid filmand fiber.No other sailmaking process approaches theaccuracy of 3DL in replicating a design shape. 3DL molds are scanned by lasers to verifyshape within imperceptible tolerances.The sail you get is the precise flying shape thesail designer created. The 3DL sails are faster and built withguaranteed repeatability. > > M o re yarn concentrated where it is needed most
Vacuum pressure within laminate Yarn in look-alike sails is laminated 2-dimensionallyand must approximate a 3-D shape. Lo a d sconcentrate at joints.3DL yarn is molded 3-dimensionally in its flyingshape. Load is distributed evenly over the entirelength of the yarn.. Atmospheric pressure 3-dimensional molding is the most significant factor in the performance advantage of 3DL.When wind pressure hits the 3DL sail, the fibers instantly assume the designed 3-dimensionalposition in space and distribute load evenly across its entire length. 3DL uses vacuum pressure from inside the laminate to pullfilms down tightly around the yarns. > > S t ructurally more e ff i c i en t

AB

Comparison of continuous yarn structure of 3DL sail (A)and broken yarn structure on segmented string sail (B). Film and yarns are bonded by heating > > L o n g - l a s t i n g > > Holds the shape longer
A B > > G reat perf o rm a n c e s
2-dimensional segments could beassembled to mimic a 3-D form (A), butonly a 3-dimensionally molded form hassmooth, compound curvature in alldirections (B). > > Lightner sails > > Wider wind range wherethe 3DL sail does not d e f o rm
The typical yarn layout in 3DL sails P o cket batten lamination The applying of yarns the mold RM mach i n e