From Core to Coating: The Art of Fly Line Engineering with Josh Jenkins

·40 min·3 clips

Josh Jenkins reveals how Scientific Anglers designs fly lines and teases new SA lines dropping soon.

The episode begins with host Marvin Cash introducing Josh Jenkins, the R&D manager at Scientific Anglers, for a detailed discussion on fly line design and manufacturing. Jenkins shares his earliest fishing memory on MacArthur Lake in Idaho and how he transitioned to fly fishing around age 10 or 11 with an Orvis Clearwater outfit. He explains his career path, starting with a mechanical engineering degree from the University of Idaho, an internship at an electronics company, and eventually landing a job at Scientific Anglers through a connection at Orvis. Jenkins describes his role at SA, which involves product development, manufacturing optimization, and quality control for fly lines. He provides a 10,000-foot view of fly line manufacturing, detailing the core, primer layer, coating application via a die, and post-processing steps like adding printed IDs and welded loops. The conversation explores the reasons behind the explosion in specialty fly lines, attributing it to diverse fishing techniques and species targeting. Jenkins discusses how pro staffers like Russ Madden and Blaine contribute to line development, with examples such as the Muskie Gen 2 line featuring a thicker running line and color-coded head for better visibility. He addresses the impact of fast-action rods on line overweighting and the importance of matching lines to casting needs. Jenkins outlines the timeline for bringing new lines to market, from taper development in about six months to technology changes taking multiple seasons for durability testing. He reveals upcoming products, including new striper lines and an intermediate line with a warm water coating for smallmouth bass. The episode concludes with Jenkins emphasizing the value of SA's customer service for helping anglers choose the right line and encouraging attendance at fly fishing shows for hands-on testing.

As heard by us

A fly-line design conversation that makes the manufacturing side feel concrete.

The conversation follows Josh Jenkins, Scientific Anglers' R&D manager, and Marvin Cash through a focused look at fly line design and manufacturing, with streamer fishing as a steady thread.

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Why you'd press play

If you want a deep dive into fly line design and manufacturing, this one starts at the core.

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