At Hall Spars we use our company’s experience and expertise to produce high performance products in an efficient way.

Our process involves building seamless tubes by laying up unidirectional pre-preg carbon around a male mandrel.

During this process, we ensure to bring you a clear understanding of the performance benefits of every detail, guaranteeing that every dollar spent delivers where it counts.

Carbon Modulus

At Hall we offer you the freedom of choice, as we work with four specific classifications of carbon modulus: standard modulus, intermediate modulus, high modulus, and ultra-high modulus. Hall’s mandrel molding process is ideal for all these materials, even with the process-sensitive more brittle ultra-high modulus materials

Smooth and Seamless

During our process, every layer of carbon is carefully compacted before the next layer is applied, ensuring wrinkle-free laminates while minimizing voids.

Our seamless masts have tooled, smooth inside surfaces, providing highly accurate surfaces for internal mounting of close-tolerance computer-machined fittings. Outside surfaces are also extremely smooth allowing them to be clear-coated without the need for weight-adding fairing.

Our seamless process at Hall maximizes mast stiffness-to-weight ratios, as our male molded masts weigh less than female molded masts when at the same bending stiffness. This extra lightness will give your yacht the edge you need to win the race.

Ultimate Precision and Refinement

Our materials promise very accurate laminate thicknesses- to a fraction of a millimetre. To optimize overall bend characteristics, strategically applied layers are placed exactly where needed, maximizing tuning and performance potential.

Our commitment to total performance extends well beyond the mast tube to the smallest of details. Knowing that a scant millimetre difference can mean a speed gain, we work closely with the boat and sail designers to optimize the relationship of mast, sail, and boat.

Autoclave Curing

Hall’s seamless masts are always cured in an Aerospace-grade autoclave, which cures laminates under elevated temperatures and pressures. Autoclave curing, at 6 times atmospheric pressure, reduces laminate void content to less than ½%. The strength difference is close to 20%.

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