North Sails is developing a revolutionary process for production of 3DL™ sails using a rotating mold. The prototype machine, RM-4, spent four years in the R&D stage. RM-4 was then used to produce racing sails for small boats during an 18 month, proof-of-concept period. RM-4 has been decommissioned and a new, radically improved machine, RM-12 is taking its place. RM-12 technology utilizes principles of Gaussian curvature to shape the surface of the drum to match the designed depth of the sail. Yarn laying heads precisely map the structure dictated by the sail's designer and the sail skins are thermoformed to the drum surface during the final lamination stage.

See how 3DL Rotary Mold sails are made

See photos of 3DL Rotary Mold products under sail

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