Why We Built a Modular Cave Reel

The Problem with Commercial Reels

Most cave reels are designed for injection molding, a process that prioritizes ease of mass production. While these reels are functional, “functional” is a minimal standard for critical life-support equipment.

The primary limitation of this design is its one-piece construction. If a handle cracks, the entire reel must be replaced. Disassembly for service or to clear a jam is often impossible. Furthermore, their bulky, awkward shape makes them difficult to pack for travel.

This frustration was the starting point for designing a new type of reel.

Modular by Design

The key difference in our reel is its completely modular, tool-free construction. The spool, frame, handles, and knob can all be disassembled in under a minute.

The benefits of this approach include:

• Easy packing. The spool with line can be packed easily, while the handles and frame pack flat. This eliminates the difficulty of packing a bulky, one-piece reel.
• Part interchangeability. A handle can be swapped for a different color to differentiate reels.
• Targeted replacement. If a knob is damaged in a restriction, only the knob needs replacement, not the entire reel assembly.
• Thorough cleaning. After a dive in a high-silt environment, the reel can be fully disassembled to wash sediment and debris from the internal mechanism.

This modularity also means each component can be designed and optimized for its specific function, rather than compromising the entire design to fit a single mold.

The Knurled Winding Knob

It may seem like a small detail, but the winding knob is knurled for a secure grip.

For any diver who has operated a reel with cold hands or thick gloves, the importance of a positive grip is clear. The knurling provides traction for cranking without slippage, even when tactile feedback is limited.

Drag adjustment is also tool-free. Adjustments requiring a specific tool are a potential failure point during a dive; all operations must be performable by hand.

Why ASA

As detailed in our post on materials, we use ASA because it withstands abuse.

Cave gear is exposed to sun, heat, impacts against rock, and various water conditions. ASA is a tough polymer that resists UV, salt, and chemicals, and it will not warp. It was selected after evaluating all other viable options.

Iteration Without Tooling Costs

Because we 3D print our reels, the design is never static. We are not locked into a single version for years by a $30,000 injection mold.

If divers provide feedback that a handle is suboptimal with certain dry gloves, we can modify the design file, print a test part, and have a new version available in days. There is no warehouse of old stock to clear first.

While large companies may plan new product versions on a multi-year cycle, we can iterate in weeks. The reel you buy today is an improvement over the one from six months ago. This is a core part of our design philosophy.

Divers Building Gear for Divers

Every design choice was born from direct experience: from packing gear bags for Mexico, to clearing a jammed reel in the Peacock system, to trying to adjust drag with numb fingers. The Camazotz primary reel was developed to be the reel we wanted to use, because it was one that didn’t exist on the market.

Check out the Primary Reels.