2004 “SmartSail” Technology: Introducing the first adaptable sail structure. What is a Fusion “m” sail? What Makes it Unique? What Makes it the Same? The Story Behind the Technology Answers to Common Questions Fusion Cuben Fibre Farr 52 Fusion m mainsail represents fundamental difference in underlying structural principles from load path jib in photo at left.

FUSION IS NOT A LOAD PATH SAIL Stress versus Strain (absorbed load versus stretch) The Load Path is not Static, it depends upon trim and sailing conditions such as windspeed and angle Load is multi-directional at every point Integrated, Multi-axis fiber system needs to address not just primary loads, but all others A sail structure must be adaptable, since there is no one fiber distribution that is perfect for every condition

Load Path Variability with Lead Position

Load is Multi-Directional at Every Point

Old World New World

Complex fiber layout produces interlocked structural system addressing loads in all directions throughout the sail.

Old World New World Mid sail detail of load path versus smart structure genoa.

Balance Fiber Density Integrated Fiber Structure High Quality Lamination Superior Engineering FUSION Lineage

Fusion is Balance Fusion “m” is the first “smart,” adaptable sail structure. As the sail is loaded, the structure moves evenly, and does not allow one part to load up more than another. By avoiding uneven loading, the sail remains easy to trim through a wider range, and does not become distorted, making for better shape life over the long haul. Fusion is the first sail to utilize an Isostrain, as opposed to a Load Path structure.

Bottom Of Range Top of Range

FUSION IS ALL ABOUT LAMINATION QUALITY A composite is judged by two qualities: strength to weight ratio, and durability. De-lamination is not an option. High quality lamination has always been a Fusion trademark. High quality lamination is all about carefully controlling: heat, pressure, and the amount of adhesive. Fusion “m” uses lamination technology more like that used by state of the art aerospace materials construction. By comparison, Fusion’s chief competitor 3DL, is a process inherently limited with respect to pressure and heat

From the beginning, Fusion has stood for state of the art lamination techniques. This is why Quantum has been able to put more fiber in more directions to achieve balanced strength, without increasing the overall weight of the sail. Fusion “m” produces a sail that will not delaminate. A more durable, easier to trim sail is the result.

ULTIMATELY, IT’S ALL ABOUT THE SHAPE The industry’s most technically sophisticated design process: A full suite of design tools, leader in VPP integration. Experience Success on a level playing field This combination is particularly suited to one-off custom projects: Get it right the first time.

Swan 45 Code 2 Fusion vs. Fusion “m”

Judson 50

THE TOOLS AND THE DESIGN PROCESS QSDG Design Program creates the geometry and defines the “design” shape S2KV takes geometry and produces pressure distribution and integrated sail forces (aerodynamic analysis)

AERO-STRUCTURES FEA software, ALGOR, computes the aero-structural mechanics of the sail, rig, and rigging, and answers the question, what is the flying shape and what is the stress- strain relationship within the membrane? Algor takes the geometry (design shape), the aero qualities produced by S2KV, and the design structure (fiber layout) specified by the designer, and calculates the amount of deformation (stretch), as well as shape changes based upon trim. All of these tools are integrated into a loop. Change the structure or the trim and assess the impact. If the structure is moving too much, change the structure, etc.

Fusion “M” Preliminary Results

FUSION IN A NUTSHELL ANSWERING COMMON QUESTIONS What is Quantum’s new product? Fusion “m” is a further refinement of the Fusion process first introduced in The primary enhancements are that Fusion ‘m” sails are the first to incorporate “smart structures” technology, and are now engineered and constructed on a sail by sail basis. This allows not only more robust tailoring of the structure to anticipated usage, but also the integration of components like batten pockets and corner reinforcements.

What makes it unique? Fusion “m” is not a “load path” sail. It is the first sail built using a “smart structure,” which addresses loadings throughout the whole sail so that loadings are shared evenly. Gone is the principle of trying to place fibers along primary stress paths. Fusion “m” is an adaptable sail structure that transfers loads as they increase instead of allowing loads to concentrate and distort sail shape. It is the first sail to strain proportionately (isostrain*), so that the mold shape does not distort (this makes it easier to trim and preserves sail shape over the long haul. It also is not assembled full size, so it can utilize state of the art lamination techniques. The result is a balanced sail structure, that is more adaptable to the ever-changing load patterns seen in the real world, and which produces a sail with a longer shape life. *Isotrain means there no distortion, but consistent deformation in all directions.

Where is it built? Designed and engineered in Annapolis, MD, USA. Assembled at a brand new, purpose built facility in Malaysia.

When is it available? Testing has been on going for the last year. Final prototypes are being tested on select boats. Limited production in the Spring, full production in the Fall of 2004.

What about Fusion Cuben Fibre? Fusion “m” is the most advanced yarn-based composite sail construction. It can nominally be compared to 3DL, Tape Drive Ultra, 4D, and other yarn-based systems. Fusion Cuben Fibre enters into another realm of composite construction entirely. It moves beyond fiber bundles (yarns), into the micro world of monofilaments. Fusion Cuben Fibre represents the absolute state of the art in composite sail construction for sails not made on a sail by sail basis. The downside to Cuben Fibre is cost. It’s sophistication and complexity means it simply cannot currently be produced on a cost competitive basis with yarn based systems. It is also difficult to work with, it requires extensive experience and engineering. The real advantage is in applications that demand high fiber density (ie: high load sails). Fusion Cuben Fibre is a big boat product..

FusionSmartSails “The nature of the structure of Fusion SmartSails is like that of a circle, of which the center is everywhere and the circumference is nowhere.” (adapted from Empedocles) Fusion SmartSails… The strength of balance.