Rock Wave Sail
Colour / Materials
Leading windsurfing brand Tushingham Sails was our first client and combined our knowledge and passion for windsurfing and design. Part of our role was to develop innovative and distinctive new sail graphics in consultation with Roger Tushingham (owner), Ken Black (sail designer) and the wider team. We also worked on various other design projects including print advertising, brochures, accessories and apparel as well as art directing a photoshoot in Barbados.
Working on all aspects of the sail development process from the brief to sketching up new ideas and
layouts with Ken Black, their chief designer to understand what we could influence and how far we could push the design concepts without the effecting the aerodynamic performance, efficiency and handling of the sail. Through numerous rounds of concepting we finalised the design and colour options ahead of ordering first sails. Panel layouts would be drawn up using a CAD system for the factory, this enabled us to finalise sail drawings, including all the material spec’s including monofilm window, taping and the various X-ply and kevlar laminates along with the new graphics. As part of the process we also reviewed material colours and introduced new ones including the cyan coloured x-ply laminate. Artwork, including the sail drawings, panel layouts and graphics are supplied to the factory in China for the prototypes to be made
before testing on the water can begin.
The Graphic elements are screen printed onto the sail and colour is introduced using various coloured, translucent and clear x-ply materials to help make the sail really standout on the water.
The different materials within the sail are designed to match the specific loads in the sail. The luff
experiences the most static load in a rigged sail, so the material needs to resist stretch and have a good hold strength. The leech has high load when the sail is in use, so the material must be very low stretch along the edge of the leech (kevlar laminate). The tack and foot areas are under constant abuse by harness hooks and the board, so this area needs a very impact resistant material (x-ply). The window area of the sail needs to have good visibility and be impact resistant (monofilm). The upper middle part of the sail has less directional loading so can therefore be made from a lighter weight materials (x-ply), but still needs to be impact resistant. Then the sleeve takes a lot of abuse from anything from rocks to broken masts so needs to be a hard wearing material.
Once the samples are received then it’s time to rig and check the sails, before passing them onto team riders to get them on the water for testing!
Following feedback, any necessary tweaks are made by Ken at his sail loft on the Isle of Wight, so the sail can be back out on the water for further testing and final amendments made before the sail is signed off and orders placed for production.