Traditional sails force 2D cloth into a 3D shape. It's a compromise.
SurgeX molds the entire sail as a single, continuous membrane.
Stitching creates weak points. Load paths are interrupted. Shape relies on seam tension, which creeps over time.
Continuous fibers run corner-to-corner. Zero structural stretch. The entire sail is a single load-bearing unit.
Before a single fiber is laid, we simulate. Our AI physics engine subjects your unique hull data to 30-knot wind loads in a virtual tunnel.
The result is a custom Load Path Map. Thousands of Carbon or Aramid fibers are laid along these exact stress lines. The film (mylar) only holds air; the fibers take 100% of the load. This is why SurgeX sails don't deform.
Solving the "Delamination" problem with chemistry.
Fibers are robotically laid dry on the base film. No heavy glue.
The entire stack is vacuum-bagged on a 3D mold to 0.9 ATM.
Heat activates the resin, fusing all strata into a single molecular layer.
FOR: OFFSHORE RACING
Maximum modulus (stiffness). Zero stretch. The choice for Grand Prix racing where shape retention is paramount.
FOR: BLUEWATER CRUISING
Impossible to tear. Excellent impact resistance. Designed for 50,000+ miles of ocean sailing.
PROTECTIVE COATING
All cruiser laminates are protected by our proprietary UV-blocking taffeta or film, filtering 99% of damaging rays.
Traditional sails don't just "break"; they die a slow death. They stretch, become baggy (draft moves aft), and increase heel while decreasing speed.
SurgeX sails lock in their flying shape. In Year 3, they retain 95% of their Year 1 aerodynamic profile. This is the highest ROI in sailing.
Robots lay the fibers, but master sailmakers finish the job. Every sail undergoes a millimeter-tolerance broadseam check and hardware stress test.
Same engineering standards, different applications.
Premium high-modulus woven polyester for small keelboats and training. Durable, reliable, and designed with the same aerodynamic profiles.
Radial cut laminates with double taffeta protection. The budget-friendly alternative to membranes, offering superior shape holding over Dacron.
Code Zeros, Asymmetric Spinnakers, and Gennakers. Designed with CFD analysis for stable flying shapes and maximum projected area.
The technology is ready. The data is verified. See what SurgeX can do for your hull.