Systems and methods of manufacturing flexible spring members for gas spring assemblies

A system for manufacturing a flexible spring member dimensioned for forming an associated gas spring assembly, said system comprising:

• a creel assembly supporting a plurality of spools containing at least one cord having an indeterminate length such that a plurality of cords are supported on said creel assembly;
• a tensioner assembly spaced apart from said creel assembly and operative to tension approximately equal predetermined length of said plurality of cords received from said creel assembly;
• a building mandrel disposed in spaced relation to said tensioner assembly, said building mandrel supported for rotation about a longitudinal axis and translation along said longitudinal axis;
• and,
• a head assembly supported in fixed relation to said building mandrel, said head assembly including an opening extending therethrough and positioned co-axially relative to said building mandrel such that said building mandrel passes through said opening in said head assembly during translation along said longitudinal axis, said head assembly operative to position and redirect said plurality of cords onto said building mandrel during translation and rotation thereof relative to said head assembly.