Sailcloth materials have evolved from flax and cotton to synthetic fibers like nylon, polyester, and Kevlar. Carbon fiber is a newer option with high strength and UV resistance. Each material has unique properties that are considered for sailmaking.
Sailcloth is the material from which a sail is constructed, in any of the various types of sailboats. Modern sails are generally made with synthetic fibers, as opposed to the naturally derived cloth canvases employed earlier in history. Modern sailors and sailmakers can choose from a wide selection of materials, including nylon, polyester, and various polymers. The properties of the fabric, including elasticity and resistance, are considered in each selection.
Historically, sailcloth was woven from flax, a substance produced by the flax plant. Linen is strong but also very heavy, and by the end of the 19th century, cotton was being used instead. The United States was one of the first countries to incorporate cotton in the manufacture of candles. The difficulty of importing flax during the war and the abundance of cotton within the country made this change necessary.
Cotton is substantially lighter and more flexible than linen, but linen is stronger. However, neither cotton nor linen are very resistant to ultraviolet (UV) light. Both are also quite susceptible to water absorption and subsequent rot. These materials were not expected to have a long life, especially in the open sea, where environmental forces were largely unpredictable and ultraviolet light from the sun was constant.
Synthetic materials emerged after the automotive boat era had already begun and have become the most popular for sailmaking. Most commonly used in wind-traveling spinnaker sails, nylons are strong, lightweight, and have a high stretch factor. Two types of polyester are used, polyethylene terephthalate (PET) and polyethylene naphthalate (PEN). PET is durable and cost effective, while PEN offers less stretch than PET. Polyethylene terephthalate is the most popular fiber choice for sailcloth, and its composition can be slightly modified to add more strength and prevent tearing.
Kevlar is the most common sailcloth choice for racing boats, as it is stronger than PET and has approximately five times the stretch resistance. P-phenylene-2,6-benzobisoxazole, also known as PBO or Zylon, is a strong polymer that offers a substantial increase in performance over most Kevlar sailcloths. It is a liquid crystal polymer (LCP), which is known for its superior strength and inherent resistance to heat and flame. PBO, however, has a worse UV durability rating than Kevlar and is one of the most expensive sailcloth fibers.
An ultra-high molecular weight polyethylene, which improves UV resistance and PBO’s price, Spectra is slightly less favorable in its tensile strength and strength. Dyneema is similar in composition to Spectra. It is also slightly more resistant to creep, the tendency of a sail to stretch and lose its elasticity over time.
Carbon fiber is relatively new to the sailcloth market and has become a popular choice despite its high cost. Its desirable properties include high strength, complete resistance to the effects of UV light, and low stretch. Carbon fiber can be made into numerous compositions, maximizing a specific property to suit the needs of each vessel. However, it is still susceptible to loss of flexibility over time.
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