Design Services
Design Services
At DarkStar Hardware, we do not just manufacture marine hardware — we engineer solutions for demanding environments. From offshore race boats to expedition vessels, we design custom components that are lightweight, durable, and purpose-built.
Whether you are solving a unique rigging challenge, optimizing performance, or integrating new equipment, we bring aerospace-level engineering to the marine world.
Example Project: Custom Titanium Pig Nose for Peacemaker
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The component shown above is a custom titanium pig nose designed for the racing yacht Peacemaker, a Ker 11.5 high-performance offshore race boat.
A pig nose, also known as a crane iron, mounts at the tip of the bowsprit and channels the tack line forward, helping ensure smooth sail deployment while minimizing friction.
- Designed in CAD
- Mounted to a carbon fiber bowsprit
- Optimized for strength, weight, and aerodynamics
- 3D printed in titanium
- Designed specifically for high-load offshore racing conditions
The geometry of the component was carefully engineered with large-radius curvature to guide the tack line smoothly around the bowsprit. This reduces friction, minimizes line wear, and improves sail deployment reliability, especially during high-load maneuvers and offshore conditions.
Reducing friction at this interface also helps lower peak loads on the line and hardware, improving durability and performance over time.
Because this component sits at the very front of the boat, weight was minimized to reduce pitching moment and maintain optimal performance.
Engineering-Driven Design
Every project follows a rigorous engineering process.
Simulation-Driven Optimization
We use engineering simulation to:
- Verify structural strength
- Optimize material usage
- Reduce weight
- Improve durability
This approach allows us to create stronger, lighter components that improve boat performance while also reducing manufacturing cost, particularly for additive manufacturing processes such as titanium 3D printing.
Capabilities
Design to Production
We can support your project from concept to finished part:
- Concept and requirements
- CAD design
- Engineering simulation
- Prototype
- Testing and iteration
- Production
Built for Demanding Environments
Our designs are used in:
- Offshore racing
- Performance cruising
- Expedition sailing
- Custom yacht builds
- Marine electronics mounting
- Lightweight performance hardware
Have a Project in Mind?
If you are working on a unique challenge, we would love to help.
Whether you are optimizing a race boat, solving a rigging problem, or building something entirely new, we can help turn your idea into reality.
DarkStar Hardware
(860) 595-8892
DarkStarHardware.com
The sail crossover chart editor uses draggable handles and a wide TWA/TWS plotting area. For best results, open this page on a laptop, desktop, or larger tablet.
What is a sail crossover chart?
A sail crossover chart is a visual guide that shows which sail or reefing setup is best for a given combination of true wind angle (TWA) and true wind speed (TWS). Racers and cruisers use crossover charts to make faster, more consistent sail-change decisions without relying only on feel or memory.
How to use this sail crossover chart generator
Use the colored range bubbles to map each sail in your inventory. The horizontal axis represents true wind angle, while the vertical axis represents true wind speed. Drag the handles to shape each sail’s usable range, rename the sail labels, change colors, toggle fills, and use dashed lines for reefing ranges or special notes.
- Add or rename each sail in your inventory.
- Drag the white handles to define that sail’s wind range.
- Use dashed, unfilled ranges for reefs, furling limits, or caution zones.
- Customize the chart title for your boat.
- Print or save the finished crossover chart as a PDF.
Why sailors use crossover charts
A clear crossover chart helps crews decide when to change from a J1 to J2, when to reef, when to move from a reaching sail to an asymmetric spinnaker, or when a sail is outside its efficient range. This is especially useful offshore, where watch teams need a shared reference for sail selection.
Tips for building a better sail selection chart
Start with conservative wind ranges, then update the chart after sailing with real data. If two sails overlap, show that overlap clearly so the crew can choose based on sea state, target angle, handling risk, or expected wind trend. Keep reefing ranges visible and easy to read so they are not overlooked when conditions build.
Advanced users can create ranges for things like water ballast or gear stacks. Keep an eye out for our rig tuning app coming soon!