A method of casting a sail comprising supplying a carrier film, supporting the carrier film along a support mechanism, forming a sail form with the support mechanism, pulling the carrier film across the support mechanism, forming a first coating, wiping the resin to control resin amount for forming the first coating, applying a yarn on the first coating in a pattern, applying a yarn on the first coating in a second pattern, dispensing a resin onto the carrier film to form a second coating covering at least one of the first pattern and the second pattern, wiping the resin to control the resin amount for forming the second coating, applying an additional element to at least one of the first coating and the second coating, applying a top film on the second coating, calendering the first and second coating, and curing the resin of the first and second coating.