Portland Pudgy Sails – Soon to Be Made In-House in Maine!

We’re excited to announce that we are transitioning to in-house sail production at Portland Pudgy! Over the years, we’ve faced supply chain challenges, difficulties with consistency and design control, and the reality that most sail manufacturing has moved overseas—even when working with U.S.-based lofts. To solve these issues, we are developing our own sailmaking process right here in Maine, keeping jobs local and ensuring the highest quality for our customers.

We’ve invested in a dedicated workspace, professional tools, and an extended arm Bernina 217 sewing machine—a workhorse that has made sails for traditional schooners here in Maine. We are upgrading it with a new servo motor for precision control and working directly with Challenge Sailcloth to source the best materials.

As part of this transition, we are focusing exclusively on the square-head sail to refine our production process and improve efficiency. Moving forward, we will no longer produce the gaff sail, allowing us to streamline operations and maintain better inventory control and design refinement.

This is an exciting step for Portland Pudgy as we develop and fine-tune our in-house sailmaking capabilities. We appreciate your support as we work through this transition and look forward to delivering high-quality, Maine-made sails soon!

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