At Dudek Paragliders we constantly strive to make our products even better. We improve both the production scheme and technology used.
To emphasise the amount of work needed to create let's say a Vox 27, it is enough to state that:
you need to draw and cut 149 elements (almost 900 metres of edges overall),
you need to make over 300 m of seams in the canopy,
you need to measure, cut, finish and connect 166 suspension lines (432 metres overall),
you need to use over 2 km of various threads,
overall length of all seams (including lines, reinforcements, suspension points and the canopy itself) amounts 800 metres.
To show you how much we care, here are some further details:
A special form is made for every part of the wing. Later it is laid on the cloth, drawn on it and cut. When preparing the elements for a single paraglider you can cut the cloth folded in two (the wing is symmetrical, so every element of its left side has a mirror duplicate on the right). If there are more wings to be made, you fold the fabric accordingly.
Cutting the lines is a different story. They are measured with a specialised, computer-controlled device and cut under a stable 5 kg tension. The mentioned device and careful procedures guarantee that final tolerance in line length does not exceed 0.15%.
This is the most time-consuming part of the production. As the seams (e.g. on the cells) can be several metres long, and the cloth is quite slippery, it is easy to make a mistake and shift one element in relation to the other.
To make the sewing as precise as possible, we decided to use a painstaking technique of marking points. These are special points drawn along the line of the future seam. The greater the curvature of a given element, the greater the density of these points required. During sewing, these respective points are harmonised in order to ensure high seam precision.
Eventually, the sail surface is smooth and free of the wrinkles that normally characterise the seams, which in turn has a significant influence on a paraglider's performance.
The type and succession of the seams is important for the durability of a wing, too. Experience gathered during obligatory inspections of our wings showed, for example, that many instances of damage were caused by the lines catching on roots or stones, with the fabric torn in the vicinity of the suspension points. To minimise this problem we altered the way these points are made. The required strength is now achieved with fewer of the needle pricks which previously weakened the cloth.
Rigging of the suspension lines can be pretty exhausting - there are several hundred of them, varying in length, colour and diameter. After assembling you join them together with the quick-links and fasten them to the risers.
And that's it - the paraglider is ready and sold as such. The pilot must individually choose carabiners, harness and speed-bar to complete his gear.