Sam Holmes Sailing · video

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Sam Holmes tours the Rolly Tasker sail loft with a staff member named Sven, walking through the full production process from design to finished sail.0:18 Software first renders a sail design in 2D, then previews it in 3D to check shape before cutting; a nesting algorithm packs panel layouts to near-zero material waste in two to four seconds.0:45 Panels are glued together before stitching to prevent movement and preserve shape, with staples used temporarily to hold ropes in position before sewing.3:45 A tri-radial sail is shown being aligned seam by seam to eliminate wrinkles and produce a smooth surface.4:51 UV strips are sealed by machine, corners are leather-reinforced by hand for offshore use, and eyelets are set with drum and metal socket hardware.6:44 The loft also runs injection-molding machines on-site for plastic hardware components, with parts water-cooled as they drop from the mold every few seconds.9:04 Sail bags are cut from panel offcuts to reduce waste.10:38 Holmes also had a UV strip and its stitching replaced on an existing sail during the visit.11:27

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