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inflatable board technology
Light, Fusion or Woven Layer Dropstitch?
At first glance, inflatable wing foil boards all look the same. But if we analyze the thickness (grammage) of the PVC with which they are built and the type of internal filament that forms their structure, we can determine three types of construction that greatly affect performance and costs. We at Reptile develop and use allof them, to deliver a complete collection.
Light Layer Dropstitch
It is a simplified structure. The Light Layer Dropstitch involves just a layer of outer material with the taut woven threads directly incorporated onto it.
Yarns woven directly onto the outer layer. In Light Layer Dropstitch, the taut woven threads are directly sewn or glued onto the top surface of the layer of PVC or similar material which forms the outside of the board.
The air chambers are formed between the outer layer with the stretched woven threads and another layer of material. When the board is inflated, the air chambers expand, and the taut woven threads create tension between the layers, giving the board stiffness.
Performance and stiffness. Although the Light Layer Dropstitch is a simplified version compared to the Fusion and Woven Dropstitch, it can still offer good stiffness and stability, especially in the Entry level sector.
The I-Ufo Zero are built with this technology.
Fusion Layer Dropstitch
Double layer structure. Unlike the Light Layer Dropstitch, two layers of PVC outer material are used in the Fusion Layer Dropstitch, but with one key difference. One of the two layers contains small holes.
Thermal fusion. The outer layers are placed together so that the holes in the top layer match the spaces between the tautly woven threads of the bottom layer. Next, heat and pressure is applied, fusing the layers together through the holes and between the woven threads.
Inner tubes and woven threads. During the inflation process, air chambers are created between the fused outer layers. The presence of the woven threads stretched between the layers contributes to the structural rigidity of the inflated board.
Stiffness and strength. The thermal fusion of the two layers through the taut woven threads increases the structural cohesion of the board. This leads to an improvement in the stiffness and overall strength of the inflatable board.
The I-Ufos are built with this technology.
Woven Dropstitch
Cross-woven structure. In Woven Dropstitch, the threads woven taut within the traditional Dropstitch structure are no longer arranged in a parallel fashion, but are woven into a cross-weave structure. This creates a three-dimensional network of threads that criss-cross each other.
Cross weaving and resistance. The intertwining of the woven threads creates a stronger and stronger structure, as the threads support each other more effectively. This increases the resistance to expansion of the air chambers when the board is inflated and contributes to greater structural rigidity.
Stiffness and performance. The cross-woven structure significantly improves the rigidity and stability of the inflatable board. This can translate into better performance in terms of control, speed and handling.
Duration. The interweaving of the woven threads also contributes to the overall longer life of the board. The sturdier structure is less susceptible to damage and wear and tear over the course of use.
The i-Ufo Pro are built with this technology.
wings technology
The Bora V2 wings are built in the best Kite and Wing manufacturing company in the world, with the most resistant materials.
Inside the Bora Wing V2 there are two air chambers, the bladders, one for the Leading Edge and another for the strut. The thickness of our bladders is 0.09 mm, a perfect combination of lightness and resistance.
The sail is made of a particular fabric, the Triple Ripstop Techfiber STW18, among the stiffest and most resistant on the market. Three vertical threads cross two horizontal ones, creating a mesh that, even if torn, resists tearing.
The structure of the Bora Wing is assembled using one of the best German-made dacron fabrics, DP175ll by Dimension Polyant. Rigid, strong and, importantly, repairable.
All the segments that make up the Bora Wing are internally reinforced on the seams by an internal Insigna AE tape.
The ends of the three points are reinforced in Kevlar, as are all the areas and seams that can rest on the ground during the inflating and deflating phase.
For the new 2024 Wing Bora we worked keeping in mind 3 important factors:
1-Rigidity
The segmentation of the Leading Edge is now much more harmonious. In the central part, where it crosses the strut, the segments have a double layer of Dacron DP176ll, an increased diameter and are connected to the strut by reinforcing webbing. In this connection area we have also changed the sewing technique, using the flat seam, which is much more resistant to tearing.
These tricks result in total stability of the structure starting from the center. The diameter of the Leading Edge tubes then gradually decreases until you reach the Tips. In this way the Bora V2 wing will be very stiff, but at the same time it will gradually release the excess wind without deforming in the centre. Added to this are the innovative Active Tips. The Active Tips are the extremities of the Leading edge, longer and thinner, which give "breath" to the wing. With an active angle, they keep the wing performing in all wind conditions, unloading the excess one, freeing the rider's arms from tension and allowing you to stay in the water for many hours, always in total control.
We've also introduced the innovative "S" Strut.
Straight strut wings suffer a lot of deformation where they are pulled by the handles. Deformation means loss of performance and stability. To eliminate this problem, we designed our Stut with curves opposite to the traction it gives during flight. The first part of the Strut is firmly connected to the Leading Edge with new reinforcing seams and webbing.
The angle of attack is designed to dissipate the enormous tension that builds up at that point during jumps, landings and pump starts. The central part of the Strut has a double dacron reinforcement and an angle that opposes the pull of the handles, eliminating any deformation.
Finally, the third part of the strut, the rear one, is sewn directly onto the sail. In this way, the control, reactivity and overall stiffness of the structure have been increased. The rear hand acts directly on the sail, controlling power distribution more effectively. Furthermore, the sail remains more anchored to the strut, more compact, decreasing its deformations.
2-Reliability
A wing must last over time. Basically it is a delicate product that is subject to wear and tear and to "dangerous enemies" such as tips (foil for example), rocks, sand and much more. However we have dedicated a whole year to improving all the aspects that lead to premature wing wear.
The seams and reinforcements are doubled. There are hundreds of meters of seams more than the previous version, numerous reinforcement / connection webbing between strut and Leading Edge, the use of Kevlar fabric on the tips, on the strut and in the area of the handles. If inflated with the correct pressure, the wing Bora V2 will also withstand any excess pressure caused by a fall or twisting, thanks to the quality of the materials used to manufacture it.
3-Performance
The rigid, harmonised, compact and reinforced structure clearly makes the Wing Bora V2 extremely performing and manoeuvrable. We have taken care of the tension of the sail by segmenting it into multiple pre-shaped and pre-assembled panels in the "belly" area, where the wing needs power but also a stable, clean and taut surface.
The Bora V2 wing is taut like a drum skin from the leading edge up to 3/4 of the sail. The back, on the other hand, has the panels assembled parallel to the trailing edge (the outgoing edge), so as to make the air exit clean and immediate. The active Tips then complete the excess wind release without destabilizing the wing. The Bora V2 is simple to sail in all wind conditions, and thanks to its tension it makes transitions with and against the wind simple. The innovative shape of the Strut facilitates control in every direction, and the three long PVC and neoprene handles allow you to navigate with only one hand and always have an available grip during Freestyle transitions.
The 2024 Wing Bora V2 required more than a year of planning and dozens of prototypes for each single size before being approved.
After the 3D design phase, what is the backbone of our Wing Bora V2 is created, the part that is not seen, the Bladders. These are the air chambers which, when inflated, give our wing rigidity. For the Wing Bora V2 we had bladders made with a special thickness of 0.09 mm, a perfect compromise between strength, reliability and lightness.
Subsequently we move on to the cutting phase of the DP175ll dacron panels, an operation which is carried out with the cutting plotter. This operation is free from any defect, as the cutting files are passed directly from the 3D program to the plotter. The assembly of the various panels borders on art. It takes a lot of experience, precision and up-to-date machines to make perfect stitching like the ones you find on the Bora V2 wing.
The Strut and the Leading Edge, the muscles of our Bora V2, are thus assembled. The Leading Edge and Strut give the shape and stiffness to the whole structure. The Leading Edge has been designed with a larger diameter in the center, which gets smaller and smaller as you get closer to the tips. This trick makes the Bora V2 very stiff and stable, but at the same time simple and light to handle in all wind conditions.
Once the frame and structure are complete, they are finally joined to the sail. Here too the 3D engineering work was high. The sail, the Canopy, is made up of about 40 pre-assembled panels, which guarantee perfect tension and stability in the front part of the wing, the "power zone", and correct release of the wind in the rear part of the wing. In addition, the smaller but numerous panels guarantee a resistance to deformation of about 5 times more than wings with larger and fewer panels.
The sail is made of a particular fabric, the Triple Ripstop Techfiber STW18, among the stiffest and most resistant on the market. Three vertical threads cross two horizontal ones, creating a mesh that, even if torn, resists tearing.
Since Wing foil is a sport that can become extreme, we have added significant reinforcements integrated into the structure to make it even more resistant and performing.
The base of all handles is Kevlar on the outside, and double dacron on the inside. Designed to last.
Kevlar has also been used to protect all Leading edge seams that may touch the ground, Tip ends, and Tip and Strut tips.
We have taken great care of the central area, the intersection between Strut and Leading Edge. This is the heart of the Bora V2, the area that must remain rigid and resist the tensions of the entire structure. All the flexural and torsional loads are concentrated in this area. The two central segments of the Leading Edge have a double layer of Dacron. The connection with the strut has double reinforcements, flat seams and reinforcement tapes. We could put carbon in it, we would. In any case, we have created one of the most solid structures on the market.