Sailboat Window Frame

In September 2025, Direct Dimensions was contacted by a boat broker who owned a Passport 545 sailboat docked at the Bert Jabin Yacht Yard in Annapolis, MD. The vessel was missing one of its port-side dodger windows and required a precisely fitted glass replacement.

To ensure an accurate match, Direct Dimensions was brought in to 3D scan the window opening, the frame’s channel, and the corresponding starboard window. From this data, we created a digital 3D pattern of the missing panel. Before committing to a glass fabrication, we partnered with our friends at Hatch X to 3D print a full-size plastic test panel based on our model. This allowed us to verify the fit directly on the sailboat and make any necessary adjustments.

Once the fit was confirmed, our team used the validated 3D-printed pattern to source a glass manufacturer to fabricate and install the final window. With a new window produced quickly and cost-effectively, the sailboat was restored to full condition and ready for resale just weeks after the initial request, which was precisely the owner’s intention.