Marblehead

The leading woven cruising sailcloth, available now in Virgin and Recycled Fiber

Technology

Boat design and rigging have evolved, necessitating new sailcloth constructions. Marblehead Recycled use the same trusted technology as the original Marblehead tightly woven sailcloth known and proven around the world. The key to shape holding and long lasting sailcloth is the number of yarn crossings, or ‘Interlockings’,™ which resist shape distortion. Challenge’s Fiber 104, and now R104 (recycled), designed for maximum fiber interlockings, creates a strong, dense weave without relying on shortterm finishes. This Interlock technology is now featured in both the Newport and Marblehead Recycled lines.

    • As boat design has evolved and rigs have modernized, it has become obvious that a more balanced AP weave would best suit today’s boats and cruising applications. Marblehead REC maintains the same technology and philosophy of our proven and trusted Marblehead LA and HA materials.

    • What matters most for a strong and durable sailcloth is the number of yarn crossings. In a woven fabric yarns pass over the first fiber and curve under the next, ‘locking’ them into each other. It is these yarn crossings, or ‘Interlockings™’, which resist shape distortion. Challenge developed Recycled Fiber R104 with the sole intention of creating a fabric with most fiber interlockings.

    • When Fiber R104 is woven in both directions of a sailcloth, it leads to a sail that relies on the strength of a tight, dense weave, rather than short-term chemical finishes. It allows sailmakers to design with lighter fabrics in heavier applications. This Interlock technology created Marblehead.

    • Marblehead Recycled: World’s first sailcloth made from fully recycled fiber.

    • Innovative Development: Created by Challenge after extensive global material research and testing.

    • Proprietary Recycled Polyester R104: Matches the properties of virgin Fiber 104, a first in the industry.

    • Performance Assurance: Marblehead REC offers exceptional performance, durability, and UV resistance.

    • Sustainability Commitment: Challenge provides these advanced recycled fabrics at the same price as virgin polyester wovens.

    • True Green Solution: Emphasizes the use of recycled materials over purchasing carbon offsets for sustainability.

    • Industry Breakthrough: Represents a significant advancement in woven sailcloth technology.

    • Long term performance for cruising sails

    • Long term UV resistance

    • Ease of Handling

    • Low stretch / high modulus due to finishing techniques

    • Decades of proven performance a life quality on the water

D6.47 Rec

D6.47 Rec

D7.47 Rec

D7.47 Rec

D8.47 Rec

D8.47 Rec

D9.47 Rec

D9.47 Rec

D10.47 Rec

D10.47 Rec

Marblehead

Fabric ID Description
 Recycled
% of Fiber 		Yarn Denier
Warp Fill 		Fabric Width
in cm
D6.47 REC 6.47 Marblehead REC 100% 250 400 54 137
D7.47 REC 7.47 Marblehead REC 100% 300 500 54 137
D8.47 REC 8.47 Marblehead REC 100% 300 720 54 137
D9.47 REC 9.47 Marblehead REC 100% 300 940 54 137
D10.47 REC 10.47 Marblehead REC 100% 500 1300 54 137

Marblehead Recycled:

World’s first sailcloth made from fully recycled fiber.

Innovative Development:

Created by Challenge after extensive global material research and testing.

Proprietary Recycled Polyester R104:

Matches the properties of virgin Fiber 104, a first in the industry.

Performance Assurance:

Marblehead REC offers exceptional performance, durability, and UV resistance.

Sustainability Commitment:

Challenge provides these advanced recycled fabrics at the same price as virgin polyester wovens.

Industry Breakthrough:

Represents a significant advancement in woven sailcloth technology.

True Green Solution:

Emphasizes the use of recycled materials over purchasing carbon offsets for sustainability

Marblehead powers the world’s leading yachts

Marblehead was designed and used on the Maltese Falcon by legendary Sailmaker Robbie Doyle. The super tight weaves, long term performance, and durability of the constructions power the yacht. The same fabric used in the maltese falcon is available for yachts ranging from 20-70 feet in single ply, and larger in 2 ply.

Decades of Proven Quality

Thousands of yachts have traveled the world, won coastal sailing races, or enjoyed weekend getaways with Marblehead.

Marblehead Recycled

The superior constructions of Marblehead, now available with recycled fiber. Challenge has taken years of Research and Development and applied Ecopak Technology to Marblehead.

Marblehead Recycled will be available from January 2023.

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.