How kites are made

Kite panels are cut with a hot iron, which seals the fibers so the edges will not fray.

stations: 10
things upstream: 50
raw sources: 14
steps from the ground: 8

The short version

Hi Fly Kites, a kite wholesaler, walks through its line step by step. Sail fabric is rolled out and panels are cut with a hot iron from templates, 8 of them for one model. Panels shuttle between sewer and cutter up to 5 times. Reinforcements get glued, sleeves and hems sewn, and fiberglass spars and bridle lines added before a final check.

Hot-cut the panels

The cutting table takes the fabric off its roll, and templates mark out each panel. A hot iron does the cutting. Modern sails are commonly ripstop nylon or polyester, with reinforcing yarns woven in to stop tears spreading.

Goes in
Nylon Polyester
Cut reinforcements and pockets

Cutters also make extra patches for the nose, spine and wingtips, plus the pockets that will hold the spars.
Sew and trim panels

Center panels are sewn together, wing panels are sewn together, and both return to the cutter for trimming. Wings then join the center and get trimmed to size. Seams have to run straight, so a sail may go back and forth up to 5 times.

Goes in
Sewing thread
Glue and mark

Those patches get glued on at the nose, spine and wingtips, and a template marks the sail. It gets a check before the last sewing.

Goes in
Adhesive
Sew sleeves and hems

Sleeves for the wing spars go on, the spine tape is sewn down and the trailing edge is hemmed. Pockets and reinforcements follow, and loose threads are cut.

Goes in
Sewing thread
Cut spars and fittings

Fiberglass spars are cut to size, and wing and spine fittings are prepared. Many modern kites use carbon fiber tube or rod, and traditional makers split bamboo.

Goes in
Fiberglass Carbon fiber Bamboo
Assemble the frame

Stand-off connectors are fitted at the trailing edge, and the spars go into the skin until the fabric pulls taut.
Set the bridle

Lines are measured, cut, attached and adjusted. A bridle divides the pull so the face of the kite tilts into the wind.

Goes in
Rope
Inspect it taut

With the skin stretched, it is easy to spot odd creases. Pockets, sleeves, fittings, end caps, knots and bridle settings each get checked.
Break down and pack

Lines are wound on reels and bags are cut and sewn. The kite comes apart for packing and hangs on racks until it ships. Every so often one is pulled at random for a flight test.

End of the lineKite

Worth repeating

One of the oldest claims for the kite credits two Chinese philosophers in the 5th century BC, who flew wooden ones.
Kite fighters in India, Pakistan and Brazil coat their lines to cut each other's kites out of the sky.
The largest kite built for Japan's Yokaichi festival weighed 3,307 pounds.