HKA KM-Packaging Sailing Team: Full Sail Toward the SuMoth Challenge 2025
As the countdown to the Foiling SuMoth Challenge 2025 begins, the HKA KM-Packaging Sailing Team is entering the final stretch of one of its most ambitious projects yet. Months of ideation, design sprints, and early fabrication have brought us to a pivotal moment: transitioning from theory to practice, from sketches to sails.
Pushing the Limits: Current Progress Across Teams
With every subteam now fully operational, the boat is rapidly taking shape — an embodiment of sustainable innovation and collaborative engineering.
One standout effort is from our rudder and flight control system team, which has engineered a multi-phase mechanism for both coarse and fine adjustment. The integration of a new pushrod system is now underway, designed to ensure smooth, precise handling under pressure.
Simultaneously, our mast and rigging unit has shortened the mast to comply with race regulations and is completing the integration of a natural flax-sealed sleeve for water-tight rope routing. On the deck, the layout and trimming crew has finalized an intuitive yet safe control line setup — cleverly using repurposed materials to reinforce our low-waste commitment.
Our trampoline team continues to impress with their innovative use of upcycled garden trampoline fabric. This central walking and seating platform not only delivers on durability but perfectly aligns with our ecological mission.
Meanwhile, the hull team is putting the finishing touches on structural reinforcement, sealing, and final surface finishing — ensuring both function and visual appeal.
Innovation in Motion: Aerocap Development
A defining feature of this year’s build is the Aerocap — an aerodynamic cockpit cover that represents a leap forward in design. Now in the advanced stages of development, the cover is shaped to integrate seamlessly with the boat’s geometry while remaining fully removable. Production is being carefully evaluated between CNC machining and 3D printing, with mold creation and mounting solutions in full swing.
Sustainable Thinking at Every Turn
From concept to construction, sustainability is a guiding principle. Every team has contributed to this goal, whether by reusing leftover materials, repurposing structural components, or selecting coatings with minimal environmental impact.
Our design also prioritizes modularity — not just for ease of assembly and testing, but to simplify repairs and extend the boat’s lifespan. Even the Aerocap is conceived to be reusable and adaptable for future configurations.
By choosing recyclable materials, shared production resources, and low-impact processes, the HKA Ecosail team isn’t just building a race-ready boat — we’re building a statement about what responsible engineering can look like.
Achievements So Far: From Blueprints to Reality
Progress since the start of the semester has been consistent and substantial. We’ve completed the design phase for all major components and transitioned into active production. Key milestones include:
- Structural completion and waterproofing of the hull
- Approval of the finalized rope-routing layout
- Initial testing of the rudder system
- Acquisition and preparation of trampoline materials
- Expansion of the team to 25 students across engineering and design disciplines
We’ve also continued to build sponsor relationships and are documenting our journey for both internal learning and public sharing — including this blog post.
What’s Left Before We Hit the Water
Although we’re nearing the finish line, a few key steps remain:
- Final integration of rigging lines, boom, and spreader
- Mounting and tensioning of the trampoline, followed by load testing
- Completion of the Aerocap through mold manufacturing and lamination
- Final waterproofing test of the hull in open water
With these last tasks ahead, the focus now shifts to execution, testing, and iteration. The team is operating on tight, coordinated timelines, ensuring every part will be ready for a seamless final assembly.
Looking Ahead
Fueled by passion, creativity, and a strong commitment to sustainable design, the HKA KM-Packaging Sailing Team is on course for success at the SuMoth Challenge 2025. As the final components fall into place, we’re confident in our readiness to compete — and to inspire.
Stay tuned for more updates from our workshop to the water.
