What are the advantages of thermoplastic resins in fly rods
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What are the advantages of Thermoplastic Resins in fly rods?. 1. The technology is exclusive to Orvis. 2. Orvis can make the lightest and strongest rods in the world as a result. How did we acquire Thermoplastic Resin technology?.

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What are the advantages of thermoplastic resins in fly rods l.jpg

What are the advantages of Thermoplastic Resins in fly rods?

1.The technology is exclusive to Orvis.

2. Orvis can make the lightest and strongest rods in the world as a result.


How did we acquire thermoplastic resin technology l.jpg
How did we acquire Thermoplastic Resin technology?

We hired US military scientists who had developed the technology for Apache helicopter rotor blades…


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US Apache Attack Helicopter

Features:

  • It is the most advanced Attack Helicopter in the world.

  • It can attack at 200mph and fly at 150 mph at ground level.

  • Originally, it was too powerful for it’s own Rotor Blades. Using epoxy resins, they disintegrated quickly at high speed.

  • New Carbon Composite blades using thermoplastic toughened resins extended blade life 4X, allowing increased payload, climb rate and cruise speed.


What do thermoplastic resins offer for fly rod design and why should a fly fisherman care l.jpg
What do Thermoplastic Resins offer forFly Rod design?And why should a fly fisherman care?


Often in materials it s what you can t see that makes the real difference l.jpg
Often, in Materials, it’s what you can’t see that makes the Real Difference

A single carbon fibre is ~1/5 the diameter of a human hair, and very brittle.


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How the Carbon Fibres get along with the Resin is very important…

CARBON FIBRE

RESIN

The Carbon Fibres are very brittle. The Resin needs to bond to them tightly and evenly to make a good fly rod.


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Thermoplastic Resins allow for a much better bond and more efficient use of carbon fibres.

  • Epoxy resins are “old” technology that fly rod makers have been using for years. ALL of our competitors use epoxy resins. You need lots of resin and lots of carbon fibres to make a good rod, but it will be heavier than…

  • A rod made with Thermoplastic resins. You need less resin and fewer carbon fibres to make a good rod, and it will be very light. ONLY Orvis is using this “new” technology.

  • Amazingly, thermoplastic resins also have the benefit of making the rod much stronger!

  • How can we prove it? Take a look at the next slides…


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Carbon Fibre Weights efficient use of carbon fibres.

“New” ORVIS EXCLUSIVE

Thermoplastic Resin Based

Carbon Fiber Material

“Old” Epoxy Resin Based

Carbon Fiber Material

2

125 g/m

95-105 g/m

2

Grams per square meter

>20% lighter in weight

Grams per square meter


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Impact Breakage Testing efficient use of carbon fibres.

Epoxy Resin System

(The “Old” technology that our competitors use)


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Impact Breakage Testing efficient use of carbon fibres.

Epoxy Resin System

Notice the breakage load on the rod is 204 grams.

And the rod broke.


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Impact Breakage Testing efficient use of carbon fibres.

Thermoplastic Resin System

(The “New” technology that Orvis uses)


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Impact Breakage Testing efficient use of carbon fibres.

Thermoplastic Resin System

Notice the load on the rod is 451 grams.

More than double the load on the epoxy resin rod.

And the rod didn’t break.


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The difference is clear… efficient use of carbon fibres.

Orvis produces the lightest and strongest fly rod on the world by utilizing the most technologically advanced resin system available.

And none of our competitors use…

THERMOPLASTICS

That’s the difference.


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Helios Rod Technology efficient use of carbon fibres.

How did we develop the new Helios rods?

Mission: Make the lightest rod in the world.

We asked 3 factories to compete:

* 1. China *

* 2. Korea *

* 3. Orvis factory in Manchester, VT, USA *


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3 Factory Competition Results efficient use of carbon fibres.

905-4 Mid Flex Rod


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Orvis' Rod Factory in Vermont are Winners! efficient use of carbon fibres.

  • The Orvis rod factory in Vermont were able to make the lightest rod, and also the strongest.

  • Orvis used a Thermoplastic Resin Scrim bonded to the Thermoplastic Main Flags to reduce weight and increase impact strength by 75%!

  • All Zero G and Helios rods will be made in Vermont.

The Secret Is The Bond!


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Current Production 905-4 Rods efficient use of carbon fibres.

* Helios 905-4 Tip 2.25 oz. *


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Current Production 909-4 Rods efficient use of carbon fibres.

* Helios 909-4 Tip 3.25 oz. *


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Rod Series Layups efficient use of carbon fibres.

1998: Trident -- Epoxy Main Flag -- Epoxy Glass Scrim

2004: T3 -- Thermoplastic Main Flag -- Epoxy Glass Scrim

2006: ZG -- Thermoplastic Main Flag -- Epoxy Carbon Scrim

ZG Helios

2008: Thermoplastic Main Flag -- Thermoplastic Carbon Scrim

Each new generation of Orvis rods has incorporated new technology that has reduced weight and increased strength!


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Helios Reel Seat Data efficient use of carbon fibres.

Helios Freshwater Reel Seat Is At Least 30% Lighter Than Any Other Orvis Freshwater Reel Seat

Helios Saltwater Reel Seat Is At Least 50% Lighter Than Any Other Orvis Saltwater Reel Seat


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Helios Guide Data efficient use of carbon fibres.

REC Recoil guides on the Helios rod are 50% lighter than guides on Zero G


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Helios New Ferrule System efficient use of carbon fibres.

Zero Gravity Carbon Flag

Compound Tapers

Zero Gravity Mandrel

Helios Carbon Flag

High Energy Tapers

Helios Mandrel

New Helios Ferrule System Advantages

Better matched carbon flag to mandrel design = 25% more ferrule engagement.

This results in better compaction, and truer inside Female Ferrule tapers for overall better fit.

Better section to section balance, which allows female ferrules to be lighter.


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Helios Rod - What is it? efficient use of carbon fibres.

1. 1st Thermoplastic Carbon Scrim rod

2. Tip-Over-Butt Rod - New ferrule system

3. Lightest rod Orvis has produced

4. Titanium stripping guides (won’t rust)

5. Lightest REC Recoil snake guides

6. Lightest reel seat Orvis has produced

7. New High Energy tapers

8. Lightest rod tube of 12K Woven Carbon

10. 25% More Ferrule Engagement

It’s the lightest and strongest rod ever made!


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