Our Membrane Technology
MEMBRANE: Beyond Material, a Revolution in Sailmaking
MEMBRANE is more than just an advanced material crafted through our innovative and exclusive technologies, it represents a fundamentally new approach to sail construction, with no dimensional limits. MEMBRANE is ART, SCIENCE, TECHNOLOGY, and CRAFTSMANSHIP combined.
At the Banks Sails lamination facility in Bari, Italy, one of the largest in Europe, we produce ultra light weight panels up to 30m x 6m, combining exceptional lightness and strength, through combination of high-pressure and vacuum.
By sourcing the finest raw materials, our sails are laminated flat, joined with bi-component adhesives, and subjected to high pressures, resulting in unparalleled performance and durability.
The Lamination Process
1. First Skin and Fiber Placement
A first skin, either Mylar film or taffeta, is laid flat on the lamination table. An automated head positions the fibers along precise curved paths. While most internal filaments remain dry and flexible for folding, the outer fiber surfaces are bonded for optimal grid strength.
2. Two-Component Adhesive Application
Our specialized polyester two-component adhesive minimizes material usage while producing stronger, lighter laminates. Unlike thermoplastic processes, this bonding is permanent and irreversible.
3. Second Skin Placement and Vacuum Application
The second skin is placed on top, and powerful vacuum pumps remove all air between the sealed layers.
4. Infrared Heating
MEMBRANE employs variable-temperature infrared lamps to only liquefy the resin uniformly across the table width, ensuring no distortions and consistent material properties.
5. High Pressure Lamination
High-pressure rollers follow the infrared stage, removing air pockets and compacting layers. Pressures reach up to 90,000 kg/sqm, maximizing fiber concentration in high-load areas—a critical step for laminating Dyneema fibers.
6. Flat Vacuum Cooling
The material cools under vacuum, resulting in a monolithic composite free from distortions caused by thermo-molded 3D laminations. For Dyneema membranes, post-curing can extend over several days.
7. Curve Cutting on Stabilized Flat Panels
Final sail curves are drawn on a stable, flat surface. This ensures repeatable, symmetrical designs and eliminates dependence on 3D molds.
The Design Process
The MEMBRANE system integrates sail design, lamination, and testing, creating a closed-loop workflow for rapid development and superior performance.
Central Design Hub
Located in Bari, (Italy), our proprietary software was developed exclusively for Banks Sails designers, supporting the entire sail design process.
3D Modeling
Designers digitally recreate the yacht’s rig, hull, and deck to produce a precise 3D model, capturing exactly how the sail will perform on the water.
Aerodynamic Analysis
CFD simulations optimize lift-to-drag ratios for the undeformed sail.
3D Fiber Layout
Fiber structures follow natural stress and load paths. Each line and curve satisfies both structural and aesthetic requirements.
Aeroelastic Analysis
Finite Element Analysis (FEA) predicts sail deformation under wind and rig loads. Subsequent CFD analysis determines lift-to-drag ratios and the center of pressure for the deformed sail.
On-Water Testing
The proximity of design, lamination, manufacturing, and testing facilities enables rapid iteration. Sometimes only hours separate a concept from actual on-water trials.
Design Philosophy
At Banks Sails, design is the art of realizing ideas conceived by the experience and talent of our team—a seamless fusion of innovation, precision, and craftsmanship.