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For the past few months I've been working on a hybrid metal / 3D printed carbon fiber composite fly reel based on the Hardy Perfect design. It is a challenging reel to manufacture using traditional means but 3D printing makes it much simpler and results in a really nice product. There are four printed parts. This component is the trick one in metal and is usually made in several parts. But I am able to print it as one part, saving a lot of production cost. Here are a bunch of parts (12 of each of the 4) all done in Proto Pasta CF PLA ready to assemble into reels.

That looks QUITE nice. I love the departure from "pure" 3d printing to a hybrid.

Thanks, or you could look at it the other way around - departure from traditional metal to a hybrid!

Here's an interesting factoid...

Throughout history, reelmakers have been the earliest adopters of new materials.

When rubber vulcanization appeared in the 1840s, a "hard rubber" or ebonite was produced. Reelmakers immediately started using it for the side plates (the black disks on my reel).

When Bayer process for aluminum first appeared in 1887, reelmakers immediately started using it for reels. At first, the market looked down their noses at it!

When Bakelite (the first synthetic thermosetting plastic) first appeared in around 1908, reelmakers started using it.

When titanium alloys first became available in 1910, reelmakers started building reels with it.

The list goes on! So it was inevitable that someone would start making 3D printed reels and reel parts. I'm glad it was me! On Saturday I'm attending an event at the American Museum of Fly Fishing in Manchester, VT - the Rare Reel Rendezvous - and I was invited to attend and demonstrate 3D printed reels. I donated one of my earliest reels to the museum and it will be put on exhibit (along with the individual parts that make it up) in the collection.

cheers,
Michael

That's even more awesome!

What is difference between Normal PLA and Proto Pasta CF PLA?

CF = Carbon Fiber

mike,

would love to see an exploded assembly on the bench of how that thing goes together......... the reel side with the gear, do you press the shaft in, or is it held with the flathead screw?

Tom C

Rather than explain it all, here are the instructions that come with the kit. They tell the whole story with photos and drawings.

cheers,
Michael

That is one of the most handsome reels you offer!
Very, very nice!