Formula Ultra

Technology

Formula Ultra is Challenge’s new multi-hull specific line of laminate fabrics developed from our Super Series GP high-end race fabrics. These styles were designed for the most demanding clients and performance applications, and are both the lightest and the highest modulus (least stretch) materials at any given fabric weight and DPI.

Less film weight, better fiber coverage across the surface, and straighter filaments like Super Series GP
For the Formula Ultra multihull series we use multiple layers of the lightest films and two layers of 200 denier inlaid X UPE fiber on either side of the structural yarns
100% UPE for warp loading bearing yarns.
UPE (UHMWPE) is one of the highest modulus fibers available, while at the same time being the most durable. The fiber has high resistance to UV and is nearly impossible to break

                    Formula Ultra
                
                                Fabric ID
                                
                                    Insert DPI

                                        Total
                                        X 45°/1.5"
                                    
                                Layers
                                Film
                                
                                    Weight

                                        SM oz
                                        gsm
                                    
                                    Width

                                        in
                                        cm
                                    
                                Formula Ultra 06
                                
                                    6,000
                                    200 D x 2
                                
                                Double UPE x
                                3.00
                                
                                    3.1
                                    135
                                
                                    60
                                    150
                                
                                Formula Ultra 09
                                
                                    9,000
                                    200 D x 2
                                
                                Double UPE x
                                1.25
                                
                                    3.7
                                    143
                                
                                    60
                                    150

Fabric ID	Insert DPI Total X 45°/1.5"	Layers	Film	Weight SM oz gsm	Width in cm
Formula Ultra 06	6,000 200 D x 2	Double UPE x	3.00	3.1 135	60 150
Formula Ultra 09	9,000 200 D x 2	Double UPE x	1.25	3.7 143	60 150

The Future is Now, and it Can’t Wait.

The legacy of Challenge Sailcloth spans four generations in the sailing textile industry. In 1917, our family founded Howe and Bainbridge, one of the first sailcloth companies in the USA. In the 1930s, DuPont® invented synthetic polyester and nylon fibers which we used to create the first Cordura® nylon mainsail cloth. Moving from tar-impregnated cotton sails to technical synthetic textiles started a new era of sailboat racing and innovation. We’ve been leaders at the forefront of textile innovation for over 100 years. Looking forward, our focus is entirely on sustainability within the textile industry.

In 2020, Challenge Sailcloth launched a new company called Challenge Outdoor, spearheaded by world champion sailor and technical textiles expert, Hale Walcoff. Hale had a vision to produce light, durable, and UV resistant materials for the outdoor sports industry using 100% recycled polyester. He wanted to produce fabrics that were best in class for the industry while being environmentally friendly. Challenge Outdoor is dedicated to reducing real-world carbon emissions and promoting clean textile technology. As outdoor enthusiasts, it is our duty to tackle the climate crisis.

This project would not have been possible as recently as five years ago, because recycled and natural component manufacturers had not achieved the performance levels required in strenuous and demanding outdoor sports. Thankfully, the global community demanded green tech, and the investment followed. Moving full speed ahead, our development efforts will be focused on sustainable innovation across our product lines. This is our new race against the clock and a challenge to the industry. Solving the climate crisis requires world-wide collaboration and we welcome you to get on board.

Sustainability Starts with You

Energy-Efficient Manufacturing

Our textiles are produced at eco-friendly facilities powered by hydroelectric energy.
Our innovative manufacturing system eliminates expensive and energy intensive drying ovens, hot rooms for curing, and many other processes needed to laminate Nylon and Polyester with solvent-based adhesive.

We maintain stock in both the U.S. and Asia for better efficiency with our manufacturing partners and brands.