A method of producing a coil for a flexible drive shaft includes: winding a roving into at least one helical groove of a mandrel； coating the roving with an uncured material； heating the coated roving to a curing temperature in the at least one helical groove of the mandrel to cure the uncured material and form a composite roving； and stripping the composite roving from the mandrel. A method of forming a flexible driveshaft for a surgical instrument is also provided and includes: feeding a plurality of flexible coils into a feeder such that each of the plurality of flexible coils are spaced from one another about a rod； rotating the rod to wind the plurality of flexible coils about the rod； and binding the wound plurality of flexible coils and rod together.
