The mandrels are built as a cone with a flange, 3D printed at varying diameters to achieve the desired nesting. The diameters are chosen with the specifications of the glass in mind so that the fiber is not coiled past its stated bend radius. Striations created during filament-based printing can cause fiber coils to get caught, so the design team opted to leverage the DLP-powered, resin-based Carbon M2 printer for a smooth finish that the fiber coils can easily be removed from.
Once coiled, the lengths of fiber can be connected in parallel to a maximum length of nearly 460m of glass, or used individually down to a length of 3.19 meters, with many other lengths possible through various combinations of fiber spools. The combination of Megladon’s fiber optic knowledge and 3D printed products created a finished product that was previously unimaginable. The 3D printing also provided for quick revision changes and support for rapid changes in product design without significant cost penalty.