It´s one year since Future Fibres first set its sights on carbon spar manufacturing and we couldn´t have imagined a more fantastic start. The vision was to build the fastest and the biggest rigs in the world and lead the next generation of carbon spar development. We have made some significant steps towards that goal. Future Fibres used the first 6-9 months to hand pick THE best composite design build team in the business. We then went on to set up a no-compromise, world class production facility, including a 50m autoclave, 60m climate controlled laminating paint booths and a 70m assembly and fit-out area.

Future Fibres prides itself on its rigorous standards in the design and construction of performance rigging. In order to push technology forward, testing is an essential part of our continuous improvement methodology. Our fibre research programme, with IMDEA and other leading European technical institutes, which has involved literally hundreds of cable tests and the study of thousands of individual fibres at the microscopic level. This has lead to the identification of performance and durability improvements which have gradually been incorporated into our production standards.

To back up the theory, in the last 10 years, we have break tested over 600 cables with a cumulative mileage of over 7,000,000 miles in an effort to understand the complexities of "nature of use" versus time and mileage, on cable performance. These Real Time Exposure (RTE) tests span all forms of sailing from America´s Cup, round the world, inshore regatta race to gentle coastal cruising; across all cable types from aft rigging to forestays, verticals, diagonals, forestay strops; on sloops, ketches and multihulls, to form the biggest composite rigging test database in the industry.

In a recent review of our test data for large cruising yachts (over 30 metres) there was clear evidence of significant improvements in cable life over time. Research on lateral rigging over the last 5 years has focused solely on diagonals (as our extensive race boat RTE programme has verified, time and again, that composite verticals suffer little or no degradation over extended periods) and we have a dataset of over 40 RTE test results totaling almost 1m miles (see box).

In our analysis, we split this set of cables by build date and found a 40% improvement in cable life for cables built in the last 3 years.

This clearly demonstrates a significant improvement in cable life, as production technology and quality assurance processes have improved over time. As composite rigging technology matures, the performance of the core material, across all fibres, is improving to the extent that emphasis is shifting to the cable ends where the metal terminations are becoming the limiting factor. This is where Future Fibres wound fibre manufacturing process has a fundamental long term advantage, offering the potential for completely composite terminations.

Our French agents, Blew Stoub, based in Lorient, have been supplying optimised composite standing and running rigging packages to the Open 60´s and offshore Multi´s for years. As cruising and club racing sailors are starting to look to composite rigging in increasing numbers the establishment of BLEW STOUB Méditerranée was a natural progression to serve this traditional sailing Mecca!

 Blew Stoub´s founder, Vincent Le Roux, approached  Escale Technique, a Marseille based rigging company, to distribute its racing products throughout the French Mediterranean. The two companies are combining their skills and experience to promote Blew Stoub's technical products together with Future Fibres' composite rigging along the south coast of France.

 Vincent comments: "We're really delighted to announce this venture as it's been on the cards for quite some time. Mediterranean clients have been demanding more technical products as well as know- how and whilst we were providing our services from a distance it has become essential to be present on site. Meeting Escale Technique, with whom we have now carried out several projects, including a Future Fibres composite retrofit on a Grand Soleil 50, provided the opportunity to create BLEW STOUB Méditerranée".

 For existing Future Fibres clients, BLEW STOUB Méditerranée adds another key location where they can access trained Future Fibres technicians for general rigging advice, support or carry out scheduled services.

 Contact : Philippe Escalle 

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www.blew-stoub.com

Building on our torsional cable capabilities has been the development and introduction, over the last 9 months, of the top down furling technique for furling loose-luffed gennakers.

Working with a number of early adopters (owners and teams) and our network of independent riggers, we have been optimising cable design and developing the technique to ensure the system can deliver repeatable, dependable results.

Andy Meiklejohn (ex Victory Challenge AC and recently joined Alex Thompson Racing) was one of the first to work with Future Fibres on the Farr 80ft, Beau Geste project last year and is a leading advocate of the system:

"On Beau Geste, in the Maxi Worlds last September, coming into the leeward mark we were head to head with a close rival. They bore away to drop their spinnaker, whilst we hardened up, furled our kite and rounded the mark boat lengths ahead. We did this 3 times to the same boat in that week! On the race course or shorthanded offshore, this system is a winner.

"The main advantage is that it makes the logistics of sail handling much easier. It reduces the need for a large crew and makes gennaker hoists and drops far easier and safer."

However, it has taken some time to get there, as Andy explains:

"Initially we set it up with some cheap cables but quickly realized that this system required significantly more torque than a traditional code sail. We ordered a new Future Fibres cable and the difference was incredible – night and day – and we used the system with great success during the Mediterranean regatta season in 2009."

But there are some keys to making this work:

Sail –  A stiffer sail cloth and a luff length to suit top-down, will increase furling consistency
Set-up – line speed for the furling unit is a priority. Too little can cause problems
Technique – it takes some crew training

However, with the right sail, a good set up and a bit of training, the system can deliver time after time, in all conditions.

Andy concludes: "I have been working with Future Fibres on the development of the cable and recently set up the system on the Lutra 80 Singularity, in Sydney. The cable we received was another dramatic step forward from the first Future Fibres cable we installed on Beau Geste last year. The moment the drum turned at the bottom, the head followed – it was incredible and improved our furling speed by 30-40%."

Into its second edition, the Barcelona World Race starts from this historic Catalan city on New Year’s Eve. With 25,000 miles of racing ahead, 10 of the 15 yachts have, once again, placed their trust in Future Fibres’ rigging for this demanding event.

Future Fibres is supplying an incredible 2 kilometers of rigging for the competing boats, ranging from full lateral sets to code cables and aft rigging. Through our long association with the IMOCA fleet, we have been developing and testing our latest range of products over a number of years, always searching for the most durable, optimised solution. This race is no different. Hugo Boss, Aviva, Veolia and Groupe Bel have been instrumental in the development of our brand new FlexC and TSC (thermoset) carbon products over the last 10 months in the lead up to the race.  They experienced the performance benefits and above all, in conjunction with our testing, built confidence in this technologically advanced product for use in a non-stop round the world event.

Andy Meiklejohn, co-Skipper of Hugo Boss explains: ‘The performance of FlexC is quite staggering. Its flexible nature makes it almost indistinguishable from a dry fibre cable (PBO, Dyneema, etc.). This is ideal for our type of yacht where boom and batten impact in the case of a crash jibe are always a real risk. Yet, FlexC is still stiffer than any other suitable product for aft rigging when comparing size and weight.’

Reliability is the buzz word of the IMOCA scene. Future Fibres does not only evoke that in our product but also in our customer’s experience when dealing with our team. We were the natural choice for Central Lechera Asturiana to manage and supply a full set of rigging, after cruelly breaking their mast on delivery to Barcelona, 28 days before the start. Future Fibres´ technical team, lead by David Barnaby, was instrumental in sourcing a suitable replacement rig whilst interfacing with our Valencia based production facility to build the new rigging. David comments: ‘Bringing a mast and rigging package together, in the most literal sense, within 2 weeks was no mean feat. From a technical perspective, finding a suitable rig, adapting it to suit the boat, engineering and building the rigging and then delivering it to the team within such a short timeframe has been a major challenge. The guys in the factory did an amazing job pulling this off, working day and night while still maintaining our high quality standards.’

Supplying Carbon, Dyneema, Kevlar and PBO stays in an array of applications to the competitors of the Barcelona World Race, once again, reinforces our “Right Fibre for the Right Application” approach to composite rigging. Each of these fibres has their own specific strength making them the right choice for their given task. Having the ability to supply unbiased recommendations on fibre choice, makes us the natural partner for teams that seek to push the boundaries of rigging technology. In turn, the IMOCA 60 fleet presents the ideal test bed for Future Fibres and a corner stone for our ongoing search for the rigging solutions of tomorrow.

Follow the BWR @ www.barcelonaworldrace.com and keep in touch with the FF rigged boats @ Future Fibres FACEBOOK.

Into its second edition, the Barcelona World Race starts from this historic Catalan city on New Year’s Eve. With 25,000 miles of racing ahead, 10 of the 15 yachts have, once again, placed their trust in Future Fibres’ rigging for this demanding event.

Future Fibres is supplying an incredible 2 kilometers of rigging for the competing boats, ranging from full lateral sets to code cables and aft rigging. Through our long association with the IMOCA fleet, we have been developing and testing our latest range of products over a number of years, always searching for the most durable, optimised solution. This race is no different. Hugo Boss, Aviva, Veolia and Groupe Bel have been instrumental in the development of our brand new FlexC™ and TSC (thermoset) carbon products over the last 10 months in the lead up to the race.  They experienced the performance benefits and above all, in conjunction with our testing, built confidence in this technologically advanced product for use in a non-stop round the world event.

The recent launch of the JV60 'Jethou' and the 39 metre superyacht 'Cinderella IV' represents two significant new projects for Future Fibres, with both pioneering the use of the company's revolutionary Under Deck Turnbuckle (UDT) system.

Plans for the UDT were announced in late 2007 and yacht designers immediately showed strong interest in the system, which removes cumbersome hardware and places it out-of-sight underneath the deck. Jethou and Cinderella IV are the first to capitalise on this technology, which not only streamlines the deck but also has a positive effect on both weight and windage.

Future Fibres' R&D director Humphrey Bunyan commented: "Composite rigging is being accepted very quickly and we are seeing a bunch of new players enter the market. Naturally we want to maintain our technical advantage and intend to keep driving our development forward at pace. The next twelve months will see us release several major developments; the UDT is just one of them.
"These projects are also great examples of a rigging company working with designers, yards, PMs and other suppliers, to produce the very best yacht possible. From conception to delivery, Future Fibres managed the relationship with all those involved and ensured that everything worked perfectly from day one. This is the direction we see Future Fibres moving in the future – taking a leading role in the whole rig package and working collectively to achieve the very best results for the customer."

Launched in May, Cinderella IV was constructed at Vitters Shipyard and features a full set of Future Fibres' rigging. With an owner's brief which focused heavily on great aesthetics, speed and long range comfort, it was felt that composite rigging was a must. Future Fibres' experience in the superyacht market, combined with the company's GL approval and weight advantage over other systems meant it was quickly chosen as the preferred supplier.

Cinderella's skipper Andy Wilson commented: "We went out with the sails on for the first time yesterday and everything went according to plan. The rigging and the UDTs look great; it makes a real difference to the line of the deck and is a very clean system. We are very happy with what we have seen so far and look forward to seeing the difference the composite rigging makes".
Cinderella's UDT design, which is the first of its type, was developed by Future Fibres' in-house engineering department, who, after presenting the idea early on in the design process, worked closely with the Tripp design office and Vitters yard to ensure a seamless installation. The result is a stainless tube, bonded directly to the chainplate, into which sits an inner adjustable tube housing the V1 end fitting.

Running in parallel, Jethou is the first in the race market to feature the UDT system. Built by Green Marine, the Judel Vrolijk designed 60 footer, launched in April, features a fully optimised race rigging package. This includes internal tangs, bullet threaders and a set of bespoke spreader ends – designed to minimise the profile of the spreader tip.

Future Fibres' Miles Amin remarked: "There has only been a handful of custom race boat launches this year, so it's great that we were able to see the UDT in action on a boat of her calibre so quickly. We worked very closely with Green Marine's engineering department to produce an ultra light version of the UDT. Constructed mainly out of composite materials, it offers a considerable weight reduction compared to a normal turnbuckle, as well as having a significant impact on windage."

As composite rigging continues to infiltrate every area of the marine industry, the push for increased customisation and flexibility also continues to rise. With these attributes at the core of Future Fibres' R&D ethos, the company has developed a system capable of accurately specifying the torsional requirements of its code cables.

Originally developed for the Volvo fleet, code cables, or torsional luff cables, have now been widely adopted for furling free-flying headsails and staysails. Suitable for boats up to 40 metres, they are designed to make handling code zero sails, gennakers and staysails far easier.

Specially engineered to transfer torque from the furling unit at the base, through the end fitting and along the length of the cable, the result can be likened to a thirty metre long propeller shaft, which can be coiled up and stored in a bag when not in use!

Through extensive in-house testing, Future Fibres has identified the specific cable characteristics required for durability, flexibility and torsional stiffness. Using a variety of materials and construction methods, the R&D team has adapted the manufacturing process to enable the precise requirements of the client or team to be met. The new range

"For a long time, Future Fibres code cables have been considered the best available, especially in the race market, where we definitely have the commanding share. However, in comparison to our current cables, and those still being sold by the competition, the new system is years ahead and means we can offer a range of options based on a boat's specific requirements." comments Alex Runciman, Head of Future Fibres' Project Management Team.

Future Fibres continues to work closely with sailmakers and furler manufacturers, which has enabled it to develop the first model capable of accurately calculating torsional requirements, based on sail size, loads and wind speeds. This in turn has enabled standards to be created for specifying cable torque and flexibility. A test regime for durability has also been developed which involves furling, interspersed with simulated 'packing' abuse, to identify fatigue issues and reduce their impact.

Alex continues: "By adjusting the way we construct the cables we can accurately build in the required characteristics to give optimum performance. The choices come down to torque, longevity and weight, and we can adjust the production variables in a number of different ways to achieve the perfect balance. We can't really go into a lot of detail about how we do it – it's a significant lead over of the competition and we want to keep that way!"

The future of Carbon is here! Future Fibres´ all new FlexC™ carbon is a true technological innovation which has been recognized this week by the METS DAME Special Mention.

A number of carbon rigging products have appeared in the last 3-4 years which all rely on standard carbon/epoxy technology. The downside with this technology is its poor flexibility which limits its applicability for certain cable types.

Having completed homologation of their TSC technology, Future Fibres R&D team set out specifically to build a flexible carbon cable. A number of months later and the R&D workshop resembling a chemistry lab rather than a rigging shop, a flexible carbon product (FlexC™) was born.