Captain Charlie Barr at the helm of Reliance during the 1903 America's Cup.

From cotton-duck to 55-knot foilers: 175 years of Cup tech

5 min read

The hull that arrived at the Isle of Wight on 22 August 1851 was unlike anything the British yachting establishment had encountered. Sharp at the bow, swelled at the stern, with a broad 22-foot beam, *America* carried two masts raked aft at three inches per foot and set flat-cut cotton-duck sails that absorbed far less water than the flax favoured by the British fleet. She won the race. In doing so, she started something that has not stopped since.

One hundred and seventy-five years of technological advancement, all flowing from a single afternoon's racing.

Around 1851, the schooner America lines up against 17 other yachts off Cowes for the race around the Isle of Wight that sparked what became the America's Cup.
Around 1851, the schooner America lines up against 17 other yachts off Cowes for the race around the Isle of Wight that sparked what became the America's Cup. | Photo: AGENCY - COPYRIGHT RESERVED

The tradition was set early. When the British mounted their first challenge in 1870 for what had become the America's Cup, after surviving syndicate members donated the trophy to the New York Yacht Club under a strict Deed of Gift, they found the defenders had already moved on. Designers Nathaniel Herreshoff, known as the Wizard of Bristol, and Edward Burgess were pushing naval architecture into mathematics and physics. Steel frames, nickel-steel construction, optimised sail plans, balanced rudders. By 1903, Herreshoff had fitted *Reliance* with hollow steel masts and aluminium fittings, chasing efficiency through every kilogram saved.

The J-Class era of the 1930s took that further. Park Avenue booms, super-lightweight aluminium masts, winches and steel-bearing rigging blocks, hull forms refined through tank testing. Metallurgy improved rigging, reduced pitch, refined chainplates. By the time *Ranger* arrived in 1937 with her extreme low-drag hull, the sailors had added scientific meteorology and structured campaign management to the technical programme. The blueprint, more or less, was drawn.

Around 1920, renowned American yacht designer Nathanael Greene Herreshoff, whose designs dominated the America's Cup from 1893 to 1920.
Around 1920, renowned American yacht designer Nathanael Greene Herreshoff, whose designs dominated the America's Cup from 1893 to 1920. | Photo: AGENCY - copyright reserved

When the 12 Metre rule brought the Cup back in 1958, designers arrived with wind tunnel and tank testing sharpened by wartime aeronautical and naval research. Large datasets were being crunched through early computers by 1974, producing Computer Performance Prediction results that shaped sail construction, aerodynamics around the mast, keel profiles and rudder design. Dacron was the sailcloth of choice, though synthetic fibres were being tested at the edges. Geared sheet winches, onboard computational power, each iteration a little lighter and a little faster.

Then came 1983. Everything shifted.

The 1920 America's Cup defender Resolute.
The 1920 America's Cup defender Resolute. | Photo: AGENCY - Copyright Reserved

*Australia II* and her winged keel remain arguably the single development that caught global attention more than any other in the modern era. Designed by Ben Lexcen following extensive tank testing at the Netherlands Ship Model Basin in Wageningen, the keel emerged from close collaboration with Dr Peter van Oossanen and Dr Joop Slooff, refining Lexcen's concept for generating lift. Paired with a sail development programme led by Tom Schnackenberg after North Sails became a global enterprise, *Australia II* ended 132 years of New York Yacht Club dominance.

Nothing after that looked the same. Glass fibre 12 Metres appeared in the 1987 defence in Perth, introduced by the New Zealand team. Dennis Conner, who won that series, added 3M riblets to the hull to improve water dispersal. Camera-based computer-aided sail-shape programmes entered the Cup for the first time.

A tank test model of the wing-keeled 12 Metre yacht Australia II, designed by Ben Lexcen, at the NSMB test facility in Wageningen, Holland, ahead of the 1983 America's Cup.
A tank test model of the wing-keeled 12 Metre yacht Australia II, designed by Ben Lexcen, at the NSMB test facility in Wageningen, Holland, ahead of the 1983 America's Cup. | Photo: AGENCY - COPYRIGHT RESERVED

The 1988 Deed of Gift match was acrimonious and strange. It accidentally accelerated development of rigid wing masts after Conner raced an advanced multihull against a 90-foot New Zealand monohull and won easily. The new IACC class introduced for 1992 in San Diego drove another wave of development across multiple Cups: narrower hulls, lighter carbon construction as standard, finite element analysis, GPS-based performance analysis, Computational Fluid Dynamics, digital weather routing, cuben-fibre sails that took sailmaking somewhere new entirely.

By 2010, the machines being built for the Cup sat somewhere between technical marvel and engineering extreme. *Alinghi 5* and BMW Oracle Racing's trimaran were giant, fully carbon structures, the American boat carrying a fixed wing mast built at the very limit of what was then possible. Wing masts on catamarans were standard by San Francisco in 2013, but the real story of that regatta was foiling. Emirates Team New Zealand figured out lift both upwind and downwind while others were still catching up.

Italia, the Italian challenger, during the 1986/87 America's Cup campaign.
Italia, the Italian challenger, during the 1986/87 America's Cup campaign. | Photo: AGENCY LTD - COPYRIGHT RESERVED

That catching up happened fast, including through the closest match in Cup history, when Oracle Team USA overcame what seemed an impossible deficit against the Kiwis. Foiling was out of the bag. The AC50 catamaran class introduced for 2017 made it an art form, teams debating foil shapes and control systems while ETNZ quietly introduced leg-powered cyclors to replace traditional arm grinders. They won.

Auckland in 2021, pandemic-delayed, brought a foiling monohull capable of exceeding 50 knots. Twin-skinned soft sails, cyclors now standard, complex PLC systems managing pre-set sail and mast rotational settings along with cunningham and outhaul tensions, all calibrated to optimum performance. Most helms moved from side to side; Luna Rossa fixed one helm on port and another on starboard. By 2024, dual helm systems were universal, and the teams were operating with digital twins, AI-assisted design, massive sensor arrays, WindSight IQ live wind visualisation and hydrogen-powered chase boats. The chase boats alone would have been a headline at any regatta twenty years ago.

The highest recorded top speed of an AC75 is 55.6 knots, set on a bear-away in the 2024 Louis Vuitton Cup by the British. Twenty or thirty years ago, these boats were doing ten to fifteen knots. The gap between those numbers is hard to fully absorb.

With the Road to Naples and the 2027 Cup now well advanced, the next layer is already visible: AI-driven design optimisation, machine-learning analysis of performance data, enhanced battery-powered onboard control systems, and the integration of women into AC75 crews under new rules.

What John Cox Stevens of the New York Yacht Club would have made of any of this is impossible to say. The America's Cup will not stop to wonder.

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