Objectives: The sails fabrication knew a significant development under the impulse of sailing races like the America’s Cup and the Volvo around the World Race. These competitions require advanced technologies to increase performance of the sails. In the paper, Reverse Engineering (RE) acquisition, CAD (Computer Aided Design) reconstruction and FE (Finite Element) analysis are used in the design phase for a spinnaker in order to maximize the performance of the sail boat. Materials and Methods: The comparison, between the design data and the characteristics in the real conditions of use of the sail (constant wind pressure acting on the sail), was carried out by the reconstruction of the three-dimensional CAD model of the spinnaker shape in full-scale, using a non contact Reverse Engineering technique, the photogrammetry and by a FE non linear static analysis. Results: The results of this study show a good correspondence between the design data and the characteristics in the real conditions of use of the sail. Significance: The described methodology is useful for sail makers. It can be successfully adopted to generate three-dimensional CAD-FE models of a sail starting from a very cheap and fast Reverse Engineering non-contact procedure.