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

Join The Butcher Shop podcast host Marvin Cash for an exclusive deep dive into fly line design and manufacturing with Josh Jenkins, R&D Manager at Scientific Anglers.

Guest Expertise: Scientific Anglers R&D Leadership

Josh Jenkins brings mechanical engineering expertise and years of hands-on experience developing fly lines for America's leading manufacturer. As SA's sole engineer, Jenkins oversees product development, manufacturing optimization and quality control for the company's entire line portfolio.

What You'll Learn: Manufacturing Secrets Revealed

Discover the complete fly line manufacturing process from core selection through PVC coating application. Learn how Scientific Anglers revolutionized the industry by moving from tapered cores to level cores with tapered plastic coatings. Understand the collaboration process between pro staff anglers and engineers that drives new product development.

Featured Techniques: Streamer Fishing Line Innovation

Explore specialized line development for musky fishing, including running line diameter optimization for powerful strip sets and color contrast improvements for low-light visibility. Get insights into new sinking line densities and the evolution from basic streamers to modern oversized flies.

Manufacturing Insights: From Concept to Market

Learn production realities including minimum viable quantities (200-300 lines annually), development timelines from concept to retail and the technology evolution from mechanical cam systems to computer-controlled manufacturing that enables rapid prototyping.

Ready to understand what makes premium fly lines perform? This episode delivers insider knowledge every serious angler needs.

Sponsors

Thanks to Schultz Outfitters, TroutRoutes and OnX Fish Midwest for sponsoring this episode. Use artfly20 to get 20% off of your TroutRoutes Pro membership.

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Helpful Episode Chapters

00:00 Introduction

05:19 From Idaho to Scientific Anglers

07:19 Role of R&D Manager at SA

08:57 Insights into Fly Line Manufacturing

14:11 Rise of Specialty Fly Lines

15:31 Collaboration with Pro Staff

19:23 Technology and Innovations in Fly Lines

23:33 Changes in Fly Design and Technique

26:59 Impact of Fly Lines on Rod Design

31:12 Timeline for Bringing New Lines to Market

32:54 Development Process for Musky Gen 2

35:18 Upcoming Products and Innovations