Design Details

The following information highlights the design details that make an AeroStar Sportkite amongst the best in the world.  The basic fabrication philosophy for each kite is always this:  To provide the optimal balance between light weight and durability.  And to achieve this goal, even the most minute detail can not be overlooked.

The predominant factor that determines a kite's quality is the sail.  Typically, I will forgo using a zillion panels or elaborate appliquéd art work.  This helps keep the weight in check while the labor savings permit using the finest materials available for enhanced durability and performance.  In essence, Aerostar Sportkites are meant to fly, not hang on the wall!

To this end, all dual-line sportkites are made from the best sailcloth presently available for kites - Icarex PC-31.  This second generation 0.6 oz. Ripstop Polyester has a Polycarbonate finish and double reinforcement weave for superior wear and stretch resistance.  PC-31 excels in the critical areas of tear strength, elongation, permeability, moisture absorption and UV fading.  So, if this fabric is so great, why are so few manufactures using it?  Simple answer - it's quite expensive!  In fact, many $300 kites do not utilize fabric as good as the $175 Spica Pro.

To ensure dimensional accuracy and repeatability during construction, all sail panels are hot cut using templates fabricated on a CAD/CAM controlled cutter.  This very precise machining process maintains tolerances to within .005" (or about the width of a human hair!).   

All sail panels are then bonded with ultra-strong 3M VHB adhesive.  The sewing is a mix of straight, zig-zag and triple zig-zag stitches that are not only aesthetically pleasing but very strong as well.  You will not find any sloppy sewing or loose threads on an AeroStar sail!  Speaking of thread, two gauges of a very strong polyester are employed.  This thread has a special bonded coating to help prevent UV degradation and is 100% cotton free to eliminate shrinkage problems when the kite gets wet.  The completed main sail is then carefully finished with a Kevlar reinforced nose along with Dacron or Mylar at all stress points.

The second major consideration on sportkites is the airframe.  Presently, I am only using two types of spars.  For most models, the choice is Easton (formerly Beman) Pro-Competition 14 linear graphite.  These spars employ a special high-modulus carbon which results in the best stiffness to weight specs of any pultruded shaft.  Without a doubt, Easton is the  leading manufacturer of competition grade archery shafts.  This means the straightness, deflection rating and wall thickness are all held to very stringent standards.  Overkill for kites?  Absolutely not!  You will appreciate the durability, wide wind range and consistent feel provided with these spars.  (Note:  Replacement PC-14 spars are readily available from Aerostar.)

For the SUL models, the awesome Sky Shark 2PT wrapped and tapered graphite spars are used.  The varying diameters of these sophisticated shafts adds stiffness were needed and reduces weight in low stress areas.  Considering their very light weight, these shafts are incredibly tough!

All airframes are further enhanced with stoppers at all connector fitting points to even include the standoffs caps (as many as 16 total per kite!).  These stoppers are made from a special adhesive-lined Polyolefin tubing that will not peel or slip.

For added durability on the Easton framed models, custom machined dual-wall leading edge ferrules constructed from 7000 series aircraft aluminum are used along with plugged lower leading edges and spreaders.  This will really give you piece of mind (and make it easier on your wallet!)  during aggressive maneuvers like tip stabs. 

As for bridles, all kites use a Dynamic 'Turbo' style bridle.  This bridle automatically adjusts the pitch (or angle of attack) in flight and is easy to comprehend and tune.  As an example, this bridle can be set with wide or narrow tow point distances while maintaining the same desired pitch setting.  The tuning possibilities are endless!

Tired of bridle paint marks wearing away after the first few flights?  Not an issue here - AeroStar bridles are color coded with permanent adjustment range marks.  This feature enables you to accurately tweak your bridle, return to the default settings or check for symmetry all without using a tape measure.  (Note:  The SUL versions of the AllStar and ZeroStar use an unsheathed Spectra bridle to save weight and reduce drag, therefore this feature is not available on this model.)

Other thoughtful AeroStar Sportkite touches include: