Daiwa rod building explained.

Daiwa rod building explained.

01. Cloth Cutting
02. Cloth Assembly
03. Cloth Rolling
04. Taping
4.1. Curing
4.2. Finishing
05. Painting
06. Handle Assembly & Finishing
07. Whippings & Guides
08. Varnishing
09. Packing
10. Quality Control

01. Cloth Cutting Many different grades of carbon cloth, called pre-preg, all varying in carbon density and resin content, some that are exclusive to Daiwa, are cut by hand into patterns that are pre-defined by our unique CAD software.
02. Cloth Assembly Once cut the cloth is laid out flat and the individual patterns are composed, again by hand. A small iron is used to melt down the resin on pattern edges allowing us to join the different shapes. Various shapes and grades are used throughout the length of the blank in order to attain the perfect action and levels of strength. Combined with our strict quality controls it is our ability to model via computer all possible variations of construction for any given style of rod that allows us to produce what we and many of our customers feel are the best blanks in the world.
03. Cloth Rolling Once assembled the cloth is then rolled onto what is called a mandrel. These are made out of stainless steel and determine the diameter and taper of the blank. Every mandrel we use has been designed by us again using CAD. We have thousands of these mandrels and are continually creating new ones as the demand for new, innovative tapers and diameters continues.
04. Taping The rolled cloth is then sealed into place with helix a special heat resistant tape. This secures the carbon sheet into place and when the mandrel expands during curing it ensures that the layers of material perfectly merge into one, removing all air and voids from the blank wall. This is critical for the strength and integrity of the blank. 4.1. Curing Curing is a precise operation, bringing the temperature progressively up to the required level, around 180 degrees centigrade and then allowing the cured blanks to cool at a required rate. The five steps of cutting, assembly, rolling, taping and curing are the most important stage of any rod design. Every pattern and blank receives a 100% quality check at each of the five stages. 4.2. Finishing The finished blank is now trimmed, sanded and joints are ground where needed. The quality control of this part of the process dictates the levels of painted finish and joint fitting of the finished rods.
05. Painting Now that the blank is complete it is time to start the decoration and application of cosmetics. We use three varieties of painting processes depending on the required appearance. We also use a combination of screen printing, stickers and transfers, all of which are our own in house design. We even use lasers to ensure that the job is as precise and consistent as possible.
06. Handle Assembly & Finishing All our handle shapes and designs are created to our own specifications. These are assembled with a variety of hidden techniques that ensure you get true performance and durability with every Daiwa rod.
07. Whippings & Guides The finished blank is now trimmed, sanded and joints are ground where needed. The quality control of this part of the process dictates the levels of painted finish and joint fitting of the finished rods.
08. Varnishing Modern technology combined with craftsmanship delivers the standard of varnished finish that you have come to expect from Daiwa. Ultra violet light chambers cure the specially developed varnish, making it harder and more durable ultimately extending its lifespan.
09. Packing Whilst every person who handles the rod inspects their own part of the process we still undertake a full quality control inspection before the rod is put into its bag. Each joint is inspected for fit.
10. Quality Control Each and every rod is checked at every stage throughout the manufacturing process.