Hall Composite Battens is the one stop shop for sailmakers and sailors. We offer a complete selection with the right batten and associated hardware to suit any purpose.

In headsails, our Flex range has the greatest difference in flexibility across its length and is for yachts over 70 feet which require great flexibility at the inboard end and stiffness at the outboard end of their jib battens.

Hall Composite Battens’ Ultraflex series are great for smaller yachts, less than 70 feet, to help control the leech of the sail with a solid laminate that tapers towards the inboard end.

Flex Battens

What they're for:

Hall Composite Batten's Flex range is specially built for longer batten pockets when a greater range of stiffness is required. This range is great for headsails on yachts over 70 feet which require long battens to help achieve the optimum sail shape.
Flex battens have the biggest difference in stiffness between the inboard and outboard ends.

Why they're great:

Our Flex battens have a hollow section at the outboard end to give extra stiffness and taper down to a solid section at the inboard end to give ultimate flexibility.

The taper is specially engineered to match the desired draft profile of the sail and ensure your sail is always producing the best aerofoil shape.

The unique honey-comb shape of the hollow section makes the battens better at resisting impact with running backstays, spreading the load across a flat space instead of point-loading on a round section.

How they're made:

When building anything from carbon, the quality of the mould dictates the quality of the finished product. so at Hall Spars, we use the highest quality polished aluminium moulds on all of our Hall Composite Battens.

Our Flex range is made by cutting long strips of pre-preg carbon fibre using a precision computer-driven cutting machine and laying these onto two flat aluminium plates. Each plate has a row of half honey-comb shaped channels carved into them. Once the fibre is laid down, the stack of carbon is vacuum bagged and put into our autoclave and cooked at 85psi or six times the normal atmospheric pressure. This ensures that we get a very dense laminate and that the fibre makes its way into the corners of the channels to create the desired shape. The cooking cycle varies in length depends on the thickness of the laminate so that the resin flows between layers and gives a consolidated laminate.

Once cooking is complete and the plates have been cooled, the corrugated sheets of carbon are joined together so that the corrugations form the honey-comb shaped cross-section. They are bonded using an extremely strong rubber-toughened-epoxy adhesive. Once the adhesive has cured, the sheet is precision water cut lengthways between each corrugation to form each batten.

Download Flex Batten Specification Chart

UltraFlex Battens

What they're for:


Hall Composite Battens' UltraFlex range is our lightest and most flexible series of battens. These are for reducing leech flap and maintaining the shape of the back part of the headsail sail where the wind exits on yachts under 70 feet.

Why they're great:

Our UltraFlex laminates give our battens outstanding strength to weight ratios, meaning we can make them lighter than other manufacturers. Every gram of weight saved aloft equals more speed on the racecourse.
Our laminates are engineered to make the battens more robust while still being light - so that they can tolerate a jib back-winding and wrapping around the forestay downwind.
The bend profile of our UltraFlex battens is achieved by tapering the laminate, not by grinding or sanding one end to make it thinner, as this makes it brittle and prone to fracture. Our battens have full-length strips of material on the outside to prevent fracturing.

How they're made:

When building anything from carbon, the quality of the mould dictates the quality of the finished product. so at Hall Spars, we use the highest quality polished aluminium moulds on all of our Hall Composite Battens.

Our Flex range is made by cutting sheets of pre-preg carbon fibre using a precision computer-driven cutting machine and laying these onto a flat aluminium plate. The strips are different lengths and weights which is how we create a bend profile to match the specifications of the sailmaker.

Once the sheets are laid, we put another sheet of polished aluminium plate on top of the stack of carbon fibre which helps to intensify the vacuum effect across the laminate. We leave the vacuum bag in place and put the stack of plates and laminate into the autoclave and cook it at 85psi or six times the normal atmospheric pressure. This ensures we get the densest laminate and minimizes void content, giving us the lightest possible battens. The plate is cut into strips using a water cutter to form the battens.

Download UltraFlex Batten Specification Chart

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