Production Tooling & Quality Systems

A summer inside a bike frame production line — building the fixtures and inspection tooling that let it start, then designing a small assembly-line fix that measurably sped it up.

Designed and owned manufacturing of 100+ parts for frame fixtures, tube-forming operations, and quality inspection processes — including 4 custom fixture designs for collaborative frame welding and tube reaming that enabled the start of production.

Reverse Engineering

Reverse engineered 12 components from imported bike frames to open up manufacturing and supply options within the Americas, reducing the cost of production.

Structural Analysis

Performed static FEA on bike frames to determine factor of safety and assess tube thickness options for weight savings.

Quality Control

Used a Creaform HandySCAN 3D scanner and VXelements software to scan and analyze production parts, running capability studies to ensure adherence to quality standards.

Designed a 3D-printed tire wedge that simultaneously centers the bike wheel and tightens the chain during assembly — combining two manual alignment steps into one, and improving line efficiency by 9.1%.