In the world of high-performance sailing, every detail can make the difference between victory and defeat. Materials, sizing, and the coherence of the entire system are fundamental elements in ensuring top-level performance and reliability in competition.
In a two-way discussion, Luigi Maffioli, Technical Director of Gottifredi Maffioli, and Raffaele Fredella, a member of the Luna Rossa Prada Pirelli shore team and mast rigger for the 37th edition of the America’s Cup, share their experiences and help us understand how material evolution has transformed the way rigging is designed and used on the world’s most competitive boats.
Why is consistency in sizing so important on a sailing boat?
When designing a sailing boat, every detail can make a difference, as Luigi Maffioli explains: “The role of a rope manufacturer must be considered within the boat’s design process. The textile components must adapt to the loads of other elements to ensure the best possible balance.”
From Raffaele Fredella’s experience, the development of specific elements, such as a loop used as a fuse with a calibrated breaking load, can be crucial in preventing an entire system from failing. This approach allows for the management of potentially catastrophic situations, highlighting the importance of precise and targeted design. Attention to detail must encompass the entire boat, not just the ropes.
It is common to observe a lack of coherence in sizing. For example, on a cruising yacht with Dacron sails and a fibreglass hull, halyards and sheets require a certain level of elasticity. Conversely, on boats equipped with carbon masts and sails, it becomes essential to opt for stiffer materials, such as Dyneema.
Dyneema SK78 or Dyneema SK99: How to choose the right material?
One of the most common mistakes in material selection is the assumption that the stiffest option is always the best choice. For example, Dyneema SK99 is 30% stiffer than Dyneema SK78. At the same diameter, this choice can drastically change working loads. Additionally, Dyneema SK78 is often preferred for its reliability in particularly high-stress situations, such as when dealing with large deflection angles.
Although transitioning from polyester to Dyneema represents a significant leap in performance, the differences between Dyneema SK78 and SK99 should not be underestimated. The issue arises when selection is made without considering the implications. It is not enough to choose the material with the highest breaking load; it is necessary to evaluate how it integrates with the rest of the system.
How has the line development process evolved over time?
In the past, rigging design was much more empirical, relying on field testing and crew intuition. Line covers were modified to provide more or less grip, but everything depended on the sailors’ experience. Today, the process has become much more engineering-driven.
It is crucial to ensure that modulus, strength, and efficiency values are reliable and repeatable. This necessity arises from the fact that modern boats are far more sophisticated. Previously, line handling was primarily done via winches, with crew sensitivity playing a decisive role. With the advent of AC75s and foiling technology, almost everything is now operated by hydraulic actuators and automated systems.
“We no longer have sheets in our hands; there are no winches to crank. Everything is controlled through hydraulic cylinders connected to the textile components, where precision is paramount,” explains Raffaele Fredella. This new approach has also led to a change in product development philosophy, as Luigi Maffioli states: “We are no longer solely focused on achieving high performance but also on ensuring reproducibility and reliability in extreme conditions.”
How have sailors’ demands evolved in line selection?
In recent years, there has been a significant shift towards product customisation. While standard sections were previously used, today intermediate sizes are now developed in increments as small as half a millimetre. This growing demand for precision comes directly from teams that request variations as small as a quarter of a millimetre.
Attention to detail is also evident in the design of line covers. During the latest campaign, a range of specific covers for certain loops was developed, refining the weave to achieve optimal grip, durability, and smoothness. The importance of dialogue between manufacturers and users is crucial, as Luigi Maffioli highlights: “In the past, products were tested on the field and adjusted if necessary. Today, we can predict material behaviour with great accuracy in the design phase, reducing the need for real-world testing and enhancing reliability.”
“This precision is not an end in itself. It is what allows us to push technology further and extend the limits of performance in the America’s Cup and ocean racing,” adds Raffaele Fredella.
How is the balance between reliability, safety, and innovation achieved in modern rigging?
Over the last decade, knowledge of materials has made significant advances, allowing for better predictions of their behaviour in real conditions. This progress is particularly crucial in critical applications, such as Dyneema stays, whose length can change depending on temperature and usage time. Addressing this challenge has required the development of mathematical models based on in-depth analysis and experience.
Thanks to these advancements, safety factors have been reduced without compromising reliability. In the industry, the safety coefficient for textile components is around 7, while for cruising boats, it is about 4. In racing, it drops to 3, and in the America’s Cup, it goes as low as 2.
This improvement allows for the use of lighter, higher-performing materials but also necessitates constant monitoring. Fredella continues: “In the America’s Cup, the team disassembles the boat every day, meticulously checking every loop, soft shackle, and connection, even analysing internal wear—a level of scrutiny that only a professional team can afford.”
For ocean racers, such as in the Vendée Globe, every design aspect must withstand for months of use without the possibility of maintenance.
From racing to everyday sailing: What can we learn?
The connection between professional racing and everyday sailing provides valuable insights for all sailors. Beyond crew members’ physical training, making informed rigging choices can lead to significant improvements.
Accurate sizing is essential to ensure both rigging longevity and proper functionality with deck equipment. A thinner rope may facilitate smoother movement but could be undersized for the required breaking loads. Conversely, an oversized line may increase friction at various passage points, accelerating wear rather than reducing it.
Material selection is equally crucial. While Dyneema SK99 may seem like the best option due to its higher working loads, it is not always the right choice for every application. Increased stiffness can place excessive stress on improperly sized clutches, leading to slippage under load. Once again, the entire system must be considered—including, for instance, switching to ceramic cam plates in clutches when upgrading from DSK78 to DSK99 halyards.
One advantage of Dyneema SK99 is in retrofit applications, allowing for small diameters even when replacing lines in traditional steel cable applications.
This attention to detail, taken to the extreme in the America’s Cup, can also make a difference on a dinghy or a cruising yacht. Understanding how to select and use lines correctly is key to enhancing performance and ensuring safety at sea.
A continuous dialogue between innovation and application
The evolution of rigging is an ongoing process. Every competition brings new challenges, insights, and solutions that, over time, become accessible to mainstream sailing.
The dialogue between manufacturers and sailors is fundamental to developing increasingly high-performance and reliable products. In-depth material knowledge and the ability to apply them correctly distinguish empirical rigging from an optimised system.
Whether for an America’s Cup yacht or a cruising boat, the principle remains the same: choose the right material, in the right size, for the right application. Because at sea, accuracy is everything.
For further information, do not hesitate to contact the Gottifredi Maffioli technical team by filling in the form below.
