RIO Product FAQ

RIO designs, engineers, and sources materials used in the production of fly lines, leaders, tippet, and flies for anglers chasing fish across every corner of the planet. While the species targeted, marine environments fished, and the RIO gear used in that pursuit may be wildly different from one hemisphere to the next, there are core product concepts and basic materials aspects that are relevant to fly anglers everywhere, regardless of their GPS location. Here are a few frequently asked questions and answers regarding fly tackle products and materials, their differentiators, and shared attributes.

ARE RIO LEADERS AND TIPPETS WITH THE SAME NAMES MADE FROM THE SAME MATERIALS?

Not necessarily. RIO sources leader and tippet from a range of suppliers and we select materials based on a range of properties. Sometimes tapered leaders are made from the exact same resins as their tippet counterparts, but often they are not. The process of making a tapered leader is much different than tippet. In fact, using the same raw material is no guarantee that the leader and tippet will have the same strength and stiffness properties. There are many variables at play that affect performance. What is most important is that we pick leaders and tippet with the best properties for a given application. For example, Powerflex Trout Leaders and Powerflex Tippet were selected to deliver the all-around performance that has made them iconic products independently of the raw materials used to make them.

WHAT'S THE DIFFERENCE BETWEEN THE NEW POWERFLEX STRONG TIPPET AND THE NOW-DISCONTINUED POWERFLEX PLUS?

Powerflex Strong Tippet is a better material than Powerflex Plus in one extremely important way: knot strength. Powerflex Plus had the highest break strength of any material we have tested without a knot, but it came with the downside of being relatively stiff. Powerflex Strong is much more supple and consequently ties much stronger knots. The “strong” in Powerflex Strong, and its performance advantage over Powerflex Plus, comes from knot strength.

Powerflex Strong’s performance advantage is obvious when testing the most insidious knot of all: the “wind knot” or simple overhand knot. We all fish with these in our tippet from time to time, often without realizing it. Powerflex Plus loses more than 33% percent of its strength on average, and as much as 55%, with an overhand knot. Powerflex Strong averages only an 11% reduction in strength.

SO WHY IS POWERFLEX PLUS TIPPET BEING REPLACED NOW WHEN POWERFLEX PLUS LEADERS ARE STILL AVAILABLE?

We recognized the advantages of Powerflex Strong Tippet over Powerflex Plus as soon as we tested the new material. We are excited about the big improvement in knot strength and are eager to make it available to our customers as quickly as possible. On the other hand, Powerflex Plus Leaders have higher knot strength than the now-discontinued Powerflex Plus Tippet. We have yet to test a stronger tapered leader product and we live by the motto “don’t fix what’s not broken.” Simply put, we are confident that the new Powerflex Strong Tippet and the existing Powerflex Plus Leaders are the highest-performance nylon terminal tackle available to fly anglers.

DO I NEED TO MATCH MY TIPPET TO MY LEADER TO FISH EFFECTIVELY?

No. There are situations where it may be an advantage to use one leader, like a Powerflex Trout Leader, all day while changing out the tippet to match a given fly or application. For example, maybe you start your day fishing a big hopper pattern close to bankside cover (and snags) where maximum strength matters most in a tippet material. Powerflex Strong Tippet would be a great choice in this situation. Later, you may want to switch to a small dry fly where Suppleflex Tippet might be the optimal choice to get longer drag free drifts. Both can be joined to a Powerflex Trout Leader and fished effectively.

I'VE HEARD THAT FLUOROCARBON TO NYLON DOESN'T WORK. IS THERE ANY TRUTH TO THAT?

No! You can absolutely tie fluorocarbon tippet to a nylon leader (or tippet). There is a widespread superstition that knots between nylon and fluorocarbon are weak and should be avoided. That is false. Fluorocarbon has several advantages over nylon. It is denser and sinks faster, less visible underwater, and generally more abrasion resistant. That makes fluoro a great tippet material for sub-surface presentations. There are many situations in which tying fluorocarbon tippet to a nylon leader is the best way to catch fish, and we encourage it.

WHAT IS MEANT BY BREAK STRENGTH WHEN REFERRING TO LINE, LEADER AND TIPPET?

The break strength (or "test" rating) printed on our leader and tippet material, fly lines (core strength), and backing is a general guideline — not a guaranteed minimum or maximum. It represent the approximate straight-line tensile strength measured under controlled conditions during production.

WHY MIGHT REAL-WORLD BREAK STRENGTH VARY SLIGHTLY ABOVE OR BELOW THE LABELED RATING?

There are several potential reasons why real-world break strength might vary from a product's labeled rating, such as:

Storage and environmental conditions: Exposure to UV light, heat, cold, and humidity over time can degrade monofilament, fluorocarbon, and braided material, gradually reducing strength below the rated value. Fluorocarbon and braided materials are generally more resistant to UV and moisture than monofilament, but none are immune to long-term environmental effects. 

Knots and abrasions: Any knot or nick in the line will reduce effective break strength, often significantly below the labeled rating.

Manufacturing tolerances — other factors and considerations: As with all precision-extruded and tapered materials, small tolerances in raw materials and production conditions may result in minor variation in measured strength between batches. For the considerations outlined below, strength should be viewed as a general guide to help illustrate diameter and application, rather than a precise measurement.

In freshwater applications, leaders and tippets are designed to create a smooth, continuous taper from fly line to fly. This taper is critical for energy transfer, turnover, and natural presentation. Because of this, diameter (commonly referenced as “X”) is often the primary consideration when selecting tippet, with strength serving as a supporting attribute. Rigging choices – such as knot selection, fly size, fishing conditions, and setup configuration can have a significant impact on overall performance.

In saltwater applications, where flies are larger, and target species require greater lifting and pulling power, break strength becomes a more primary consideration. Anglers typically select materials based on pound test to ensure the ability to effectively fight and land larger, more powerful fish.