FROM ONE INTO THREE
From the 2015 bluefin drive, we developed three entirely new drives packed with innovation. I lead the MDGT and MD180 development programs.
Kickup fins
We patented a design allows you to hit underwater objects without breaking the drive. This feature led to a 98% reduction in warranty failure and a substantial competitive advantage. We developed all new kickup fins that gave more power for the same amount of pedaling.
Maximized Compatibility
The kick-up feature needed to be compatible with all three new drives, fit into the pre-existing opening in the boat, and accommodate mechanisms that allow the drive to rotate 180° and 360°.
Adjustable Crank
The pedals are adjustable to fit different leg lengths. Users were struggling to understand how to use them. We patented a new mechanism inside the crank that allows the push button to adjust the leg length. I was responsible for delivering the project from concept through 120,000-unit production.
cost concious innovation
Previous generation drives used costly, custom stainless-steel chains that are difficult to source, for the 360, we used standard stainless-steel cables at 1/5 the cost. I was responsible for testing and proving this system worked across a range of tests including a lifetime simulation of pedaling millions of cycles. This formed some of the core breakthrough technology that kept the 360 a cost-effective innovate solution.
rotation 180 check
Tooling family feature geometry checks
3D print fit check
sand ingress testing
sand testing 360 sprockets
cycle testing POM 25%GF chain gears
3 million cycles later, 17-4 SS mast snapped
Fin warp afte 1,000,000 cycles
machined sprockets for less bearing wear on GF parts
new pedal invention anti-rotation bungee
Drive bag samples
detail drawing crank core
First production batch
MIRAGEDRIVE 360 INTRO
MIRAGEDRIVE 180
TESTING
UV TESTING • FATIGUE CYCLE TESTING • FEA • IMPACT TESTING • TENSILE TESTING • FIELD TESTING • SAND & SALTWATER TESTING • FMEA • RUNNING OVER STUFF
PRODUCTION PROCESSES
INJECTION MOLDING • ALUMINUM EXTRUSION • ANODIZING & HEAT TREATING • STAINLESS STAMPING • CNC MILLING • OVER-MOLDING • LASER ETCHING • CUSTOM STAINLESS HARDWARE • PRECISION MOLDING (0.002”) • PASSIVATION AND ELECTROPOLISHING • DIE CUTTING
Credit to Phil Dow inventor of the MirageDrive 360