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 mainsails, our Compression range is for use as full-length battens for supporting square topped mainsails or connecting to sail cars.

Our Flex range has the greatest difference in flexibility across its length and is for long intermediate battens which require great flexibility at the inboard end and stiffness at the outboard ends.

Hall Composite Battens’ Ultraflex series are great as flutter battens to help control the leech of a mainsail with a solid laminate that tapers towards the inboard end.

Compression Battens

What they're for:

These battens are built to handle compression loads. When choosing battens for a mainsail, these are the ones for a gaff batten for a square-top mainsail, for connecting to mainsail cars and for anywhere that battens run all the way from the leech to the luff.

Compression battens come in a range of sizes and stiffnesses (see link to chart below) to suit yachts from 40 foot upwards. Each batten size has many different laminates that to match the bend profile specified by your sailmaker.

Why they're great:

The smooth and shiny surface gives almost no friction against the sail, so they "pop" from side to side much more easily than other manufacturers when you tack or gybe in light air.

Our manufacturing method produces the best quality laminate and low resin content giving the best strength to weight properties.

Sections of batten are easily joined to make whatever length you need.

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.

Long strips of pre-preg carbon fibre are precisely cut using a computer-guided cutting machine. These are laid one at a time onto a former, which helps us to more accurately place the layers in the correct position and then placed into two halves of an aluminium mould. Then we place a strong plastic bladder into the bottom mould and connect the moulds together.

Once the halves are connected, we connect a hose to the bladder and pump it up to 85psi or six times the usual atmospheric pressure. Then the mould is rolled into our custom built oven and cooked to a precise heating and cooling schedule so that the resin flows correctly between the layers and creates the best laminate for strength and flexibility without being brittle.

Download Compression Batten Specification Chart

Flex Battens

What they're for:

Hall Composite Batten's Flex range is specially built for long intermediate battens in mainsails. When choosing battens for a mainsail, these are the long intermediate battens that go between the full-length compression battens.

Flex battens have the biggest difference in stiffness between the inboard and outboard ends.

These battens are for use on all yachts from 12-foot skiffs to 100-foot Supermaxis and Superyachts.

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 "flutter battens" for reducing leech flap and maintaining the shape of the back part of the sail where the wind exits.

These battens are for use on all boats from Optimists to 100-foot Supermaxis and Superyachts.

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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