Skip to content
LoadX Studio

Manufacturing Process

The Central Kitchen Concept

Section titled “The Central Kitchen Concept”

LoadX operates as a specialized manufacturing partner for sailmakers worldwide. Think of us as your Central Kitchen. You possess the local market knowledge, the branding, and the finishing skills. We possess the heavy industrial machinery required to produce high-tech membranes.

We handle the capital-intensive, high-precision lamination process, delivering a “Membrane Blank” ready for you to finish.

Our Process

Section titled “Our Process”

  1. Digital Design We start with a 3D mold. You can upload your design files (AzureProject, SailPack, Prosail) via our Partner Portal, or provide boat specs for our design team to create an optimal shape for you.

  2. Automated Fiber Laying Data is sent to our proprietary Robotic Gantry System.

    • The machine lays dry fibers with 0.1mm precision.
    • Yarns are tensioned individually as they are placed to ensure zero crimp.
    • Paths are non-linear, following the complex curved stress map of your sail.

  3. Vacuum Consolidation The loose fiber and film stack is covered with a vacuum bag.

    • We pull a near-perfect vacuum (approx. 1 bar of pressure).
    • This removes trapped air bubbles which could cause delamination.
    • High pressure consolidates the layers, forcing the fibers into a tight, flat ribbon.

  4. Thermoset Curing The vacuum-bagged membrane is heated to activate the resin matrix.

    • Our Thermoset Resin undergoes a chemical cross-linking reaction.
    • Once cured, it cannot be re-melted. This provides superior heat resistance and bond longevity compared to thermoplastic (hot-melt) glues.

  5. Quality Control Every membrane undergoes a rigorous inspection:

    • Translucency Check: To ensure consistent resin wet-out.
    • Load-Path Verification: Confirming fiber density aligns with the design file.
    • Measurements: Verifying luff, leech, and foot lengths against the order specs.

The Facility

Section titled “The Facility”

Our manufacturing takes place in a Climate Controlled Clean Room.

  • Temperature & Humidity: Strictly regulated to ensure consistent resin cure times.
  • Dust Control: Creating a contamination-free environment for maximum bond strength.

By centralizing production in our high-volume facility, we achieve consistency and quality that is impossible to replicate in a typical dusty sail loft floor.