Seamed sail and method of manufacture

A method for manufacturing a sail of a plurality of panels, said sail having at least three corners, said method comprised of the steps of:

• a. securing on a flat surface a series of substrate panels corresponding to at least a portion of a sail, wherein a substrate seam between each substrate panel extends from a first edge to a second edge of said substrate panel;
• b. placing a first strip of a two-sided glue release medium on one side of an anticipated seam, said first strip being placed on one side of said anticipated seam on a substrate panel;
• c. laying down with a glue or an adhesive material a plurality of continuous filament yarns on said substrate panels to follow primary and/or secondary load path for said sail when said sail is in use for its intended purpose;
• d. overlaying for each panel a second strip of a two-sided release medium near one edge of said first strip of said two-sided release medium and at top of said continuous filament yarns, wherein said second strip is next to said anticipated seam for a precursor panel contiguous to a precursor panel with a first strip thereon;
• e. securing adhesively a layer of a second film or a second sheet of reinforcement material on top of said plurality of continuous filament yarns thereby obtaining a plurality of precursor panels for said sail;
• f. cutting each of said precursor panels with a broad seam for said precursor panels for said sail along a seam between said first and second strip of said two-sided release medium;
• g. removing said first and second strip of said two-sided release medium;
• h. gluing and broad seaming overlappingly each of said precursor panels to its next contiguous precursor panel to form a sail of a plurality of panels wherein each panel joins the other with an interior seam having yarn to yarn relationship.