Tech-Talk: the Technology behind the New Integrated Mast System

Performance begins long before the foil touches the water. Discover how advanced materials, aerospace-grade bonding technologies, and innovative manufacturing processes come together to create the new SABFOIL Integrated Mast System.

"The use of dedicated molds for the mast and the plate enables the geometry, fiber architecture and laminate schedule of each component to be independently optimized for its specific structural function before being permanently bonded using aerospace-grade structural adhesives.

This manufacturing process achieves mechanical performance equal to or exceeding that of a one-piece monocoque construction, while providing superior load distribution across the assembly. By eliminating localized stress concentrations and ensuring a more uniform transfer of forces, the structure delivers enhanced fatigue resistance, greater long-term reliability, and improved vibration damping under dynamic loading.

The structural adhesives employed in our process are the same class of high-performance bonding systems used for decades in primary aerospace structures, including fuselages, wings, and empennages, where long-term durability, impact resistance, and structural integrity are critical requirements.

Another distinctive feature of our production process is our in-mold painting technology, a manufacturing solution that is unique within the hydrofoil industry. Unlike conventional post-painting, the graphics are integrated directly into the molding process, producing a perfectly flush, zero-relief surface with no additional coating thickness or surface discontinuities.

The result is an exceptionally smooth hydrodynamic profile that minimizes surface turbulence and skin-friction drag, promotes a more stable laminar flow regime, and delivers measurable benefits in efficiency, control, and overall on-water performance.”

Simona Garattoni, SABfoil Materials Engineer

Simone Bottoni, SABfoil Aerospace Engineer