JOURNEY OF A SAIL

Have you ever wondered how many hands touch your sail before you even unroll it on the beach for the first time? At Point-7, we take you behind the scenes to our production facilities at Aquadynamics in Sri Lanka, where precision, expertise, and dedication come together to create a windsurfing sail like no other.

A windsurfing sail isn’t just another factory-made product, it’s an intricate, handcrafted masterpiece. While components are assembled in series, every single sail is meticulously crafted, piece by piece.

Bringing a sail to life is a journey filled with countless steps. From the moment it is designed to the first time it catches the wind; each phase is executed with passion and precision.

The factory is a huge structure with over one thousand people working. We remember the first time we were at the factory, just looking at the number of bikes, which now turned into motorbikes, cars and tuk tuk, seemed like entering a small town. Time has evolved, but still, how sails are built is still like 20 years ago as there is no technology that can make such a handcrafted work, especially for the numbers of our industry.

It all starts with feedback—directly from our customers and from elite PWA pro riders pushing the limits of performance. Hours of testing in diverse conditions, racing, jumping on the course, traveling, nights at the loft, and engaging with windsurfers worldwide shape the final product. This invaluable data is fed into the design process, where new files are created, graphics are refined, and materials are sourced globally. Prototypes are evaluated rigorously—sail, tweak, test, repeat—until perfection is achieved. It’s a nonstop work that is not rushed, but where the developers are always thinking about the next steps to improve the rig. It’s not only the sail.

When smiles light up the water, production is given the green light. There are so many details to give to production that the worksheets are full of details, as also the quality of the thread and colour need to be explained for each part of the sail, and this can even change according to the size, to improve the performance, quality and looks.

Once the final designs are locked in, the production facilities take over. With around ten sail lines and eight sizes per line, that’s eighty unique models. Each race sail comprises over two hundred individual patches—if you factor in hardware, battens, and reinforcements, that number climbs to 250-300 per sail. Multiply that by eighty models, and you’re looking at over 20,000 individual components. And that is before we even count sail bags and packing!

Contrary to widespread belief, sails don’t just emerge from machines at the push of a button. Each file undergoes scrutiny by production experts to ensure flawless execution. They assess every detail—verifying patterns, identifying potential challenges, and ensuring seamless print integration across materials as the panels once assembled have shapes.

Graphic design for a sail isn’t just about aesthetics—it’s an engineering challenge. Every print must align perfectly across panels and materials, considering shading variations and shape contours. Unlike simple scale-downs, each sail size demands a custom redraw of its graphics to maintain fixed points such as boom openings and clew positions.

Did you know? A single sail can require up to 30 individual prints per site, effectively doubling the number due to port and starboard orientations. With eighty sail models, this amounts to an astronomical number of screen prints, each carefully prepared and aligned for a seamless look. Also, when making graphics of the sail, you need to consider the fact that the stitching, prints and materials cannot be in some places, and every change made in graphics needs to be evaluated to make sure that it does not affect the performance. The materials ordered need to fit the graphics style, but in the first place they need to be working efficiently for performance. In our case performance to make sure our sails are giving the biggest wind range, created by power and control, is priority to everything.

The materials come from five different nations. China is providing the rubber protections, USA is where we decided to have our monofilm made, some other components like carbon are made in Italy and Germany, some of the other components are made in Sri Lanka. So, to get everything in time in production is also one big challenge like shipping, production from everyone is months, and when the style changes every twelve, it’s a race.

Nesting—the strategic arrangement of sail panels on raw material—is a skill in itself. With material rolls typically maxing out at 1.4 meters in width, every piece must be positioned for maximum efficiency, minimizing waste. While computer algorithms assist, human expertise still reigns supreme in this process. Each production is different according to the order of sails models, and when nesting there is a total cross over of materials taking account of the full order, not one sail at the time. A job that needs to be done let’s say for every 300-500 sails at the time, as this is what fits in a container. Imagine the stock needed, and the calculation in ordering materials 9 to 12 months ahead over forecast which depends not only on a global scale of economy and geopolitical happenings, but also if it will be a windy season and on how many kiters and wingers will be back to the roots of the pure sport of windsurfing to get some real power over the water!

Once the nesting is finalized, material rolls stretch across kilometers before being fed into cutting plotters. Each cut piece is scrutinized for perfection, ensuring the monofilm and other materials remain pristine. The monofilm alone passes through 177 different hands before assembly. If a single person attempted to build a sail solo—with today’s precision and detailing—it would take 597 hours per sail with the type if prints and finish. Made solo without this finishing expectation, it would take 3-5 days but would look poor compared to what we are used to. If a panel presents a ding or a pinch, it’s thrown away and cut again. Unfortunately, monofilm are not easy to be produced and in one roll there can be many areas which needs to be discarded. Sometimes they are minor pigment mistakes or already pinches in the material. There are not many suppliers who are now producing these materials as it is not a straightforward process. If you try to take 1m of monofilm in your hand, and try to just pick it up and put it down on a different place, you will realize how hard and careful the process of making a sail is, in just trying not to crush or scratch the materials during the process. It can’t be ironed. Each panel after cutting, has a thin paper place over and under attached with some tape in order not to scratch it. Each time it’s being worked, this paper is taken out and then placed back.

Some reinforcements, such as Dacron tapes and internal stripes, are still cut by hand for speed and often accuracy as materials can still move or stretch under a plotter.

Sail printing is no quick process. Each panel requiring a four-color design must be printed four separate times, with each layer drying for four hours. That means 16 hours per side, 32 hours for a complete panel. Multiply that across all sails, and you realize the sheer magnitude of effort involved. The screens need to be made for each print, each colour, each sail size, and every time that a colour needs to dry up, it needs space to rest to let the next panel be printed. Space for the screens to be stored when not in use. Imagine just printing our Italian flag on our sails on both sides. Its 12h for each side, meaning that the panel needs to stay in the printing department 24hours of work, before being ready.

Once printed, panels undergo yet another quality check—only flawless prints make the cut, otherwise once again this panel, needs to be re-cut, and printed slowing down the production process. Does it happen? Again. Take a panel in your hand and see how difficult is to handle without making one small crease. They are professional and experienced, but human.

Battens are the backbone of sail structure, and their production is a 24/7 operation. With an average of five battens per sail, each varying in length, stiffness, and material composition, this process is a blend of technology and meticulous handcrafting. In total, four hundred different batten specifications must be produced and refined.

Think a sail bag is a simple add-on? Think again. Each one undergoes the same rigorous process as sails—custom printing, material selection, nesting, cutting, and assembly. Even the zipper placements are meticulously planned to accommodate various diameters of the sails according to their size once rolled.

With all components ready, assembly begins. Eight specialized teams manage different sections, ensuring absolute precision at every stage. There are over 80-100 people working along this production assembly section dedicated fully to windsurfing.

1. Panel and Mast Sleeve Preparation – These two critical sections are assembled separately before being stitched together with pinpoint accuracy.
2. Batten Pocket Installation – The first major structural component added to the sail. There are so many different constructions, and they need to follow the profile of the panels. This also needs a lot of experience as again; the sail is not 2d.
3. Mast Sleeve Integration – The most delicate part of assembly, requiring expert hands to achieve the perfect alignment. There are very few people who do the mast sleeve assembly as its difficult and needs to be precise. Especially with race sails, where a mast sleeve is not easy to fold and attach over the mast body. 1mm mistake can be seen with a huge wrinkle once rigged. There needs to be the right starting point, a right pressure and technique.
4. Final Stitching & Reinforcements – The sail takes its final shape, with every stitch ensuring durability and performance.

At this stage, 220 individual pieces have been seamlessly combined, having passed through 180 skilled hands, five departments, and thirty workstations—all while maintaining absolute flawlessness.

The sail now undergoes meticulous final refinements:

• Thread Trimming & Eyelet Installation – Precision cutting and reinforcement additions ensure longevity.
• Polishing – Fingerprints and markings are removed using coconut oil, leaving the sail spotless.
• Batten & Camber Insertions – The final structural elements are added including the eyelets.
• Quality Inspection – A final, exhaustive check ensures every detail is perfect.

Once approved, the sail is carefully rolled with protective carton and paper, fitted with stickers, accessories, and spare parts, and placed in its customized sail bag. Each sail is individually boxed with serial number tags, documentation before embarking on its next voyage—whether by air or sea—to windsurfing enthusiasts across the globe.

But the journey doesn’t end there. Each year, new patterns, graphics, materials, and hardware innovations bring fresh challenges and refinements, ensuring the relentless pursuit of windsurfing excellence.

The next time you rig up your sail, take a moment to appreciate the engineering marvel in your hands. Behind every panel, every stitch, and every curve lies the dedication of hundreds of skilled craftsmen, designers, and innovators. Is there a small ding on the monofilm, now you could imagine why. Don’t worry though, the monofilm are now for example on our sail, full anti-uv laminates, and if there is a mark it will stretch back with some use, and it will not create a chance for future cracks.

This is not just a sail—it’s a performance masterpiece forged by passion, expertise, and an obsession with perfection.

Ride and enjoy the experience of your sail, which has been traveling a lot of kms of the seas already, and what might look expensive, has behind a lot of work and costs.

PH TOMMY DELLA FRANA