Sam Holmes Sailingvideo
The fascinating process of how sails are made at Rolly Tasker. (VR180 for viewing on a VR headset)
September 10, 2025 · 12 min · 11K views · Phuket
What this video covers
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.0:05 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.0:26 Panels are glued together before stitching to prevent movement and preserve shape, with staples used temporarily to hold ropes in position before sewing.3:43 A tri-radial sail is shown being aligned seam by seam to eliminate wrinkles and produce a smooth surface.4:53 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.9:09 Sail bags are cut from panel offcuts to reduce waste.10:50 Holmes also had a UV strip and its stitching replaced on an existing sail during the visit.11:27
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