Patent ID: 7419561

Claim:
A method of casting a sail comprising: supplying a carrier film; supporting said carrier film along a support mechanism; forming a sail form with said support mechanism; pulling said carrier film across said support mechanism; dispensing a resin onto said carrier film to form a first coating; wiping said resin to control the amount of resin for forming said first coating; applying at least one yarn on said first coating in at least one first pattern; applying at least one yarn on said first coating in at least one second pattern; dispensing a resin onto said carrier film to form a second coating covering at least one of said first pattern and said second pattern; wiping said resin to control the amount of resin for forming said second coating; applying at least one of a tack, a clew and a head corner to the at least one of said first coating and said second coating; applying a top film on said second coating after applying the at least one of a tack, a clew and a head corner to the at least one of said first coating and said second coating; calendering said first coating and said second coating; and curing said resin of said first coating and said second coating.