From one into three..
From the 2015 bluefin drive, we built three entirely new drives packed with innovation. I lead the MDGT and MD180 development programs.
Reversing kickup fins
The invention and execution of the kickup fins (from rigid fins) directly lead to a 98% reduction in warranty failure and a substantial competitive advantage. The fins could glide over anything over.
The patented design allows all three drives to hit underwater objects without breaking the drive. We developed all new fins that give higher thrust for the same amount of pedaling.
User focused invention
MirageDrive pedals are adjustable to fit different leg lengths. I patented a new mechanism inside the crank that allows the push button to adjust the leg length.
Sharing components
Using a top-down modelling strategy in SolidWorks allowed parts to be shared cross-platform decreasing cost and manufacturing risk. Integrating legacy components with new designs built in different factories.
Cost conscious innovation
Previous generation drives used costly, custom stainless-steel chains that are difficult to source, for the 360, we used standard wire cables at 1/5th production cost. I was responsible for testing and validation the 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.
Good... in theory
Rendering, FEA and 3D models are nice but there is a large gap between what works on the screen and what worked in the real world. This gave me a basic framework to build functional prototypes.
Test to failure in the real world
Pins slip out of alignment, new suppliers have holes in extrusions, materials don't meet spec and crack, marine grease breaks down, TPE fins warp overtime, high strength masts snap, hidden welds break, Florida UV damages type II anodizing.
A thorough testing phase revealed issues when the design was exposed to the real world. I setup a group of pro testers and put thousands of miles on the drives in real world scenarios across the US. We built cycle testers specifically for drives to do millions of miles in a few weeks.
Fatigue cycle test • UV test • Tensile test • Sand ingress • Saltwater corrosion test • Fin thrust test • Field test
Build at scale
15 new injection molds, extrusion profiles, 53 detail & assy drawings, 5 QC drawings, international supply chain. There was a lot to make sure went right.
I was responsible for delivering the drives, from concept through 80,000pcs/yr production.
I built drives over and over with the factory assembly team to improve cycle time, balance the work cells, and design fixtures.
Drive bag samples
detail drawing crank core
MIRAGEDRIVE 180 INTRO
MIRAGEDRIVE 360 INTRO
Credit to Phil Dow, inventor of the MirageDrive 360
TOOLS - urethane casting • machine shop • keyshot • SolidWorks • sketch • 3D print
DESIGN - user needs gathering • concept design • patent writing & drawings • prototype development • advanced surface CAD
ENGINEERING - 60x detail drawings • costed BOM analysis • vendor quoting • supply chain management (CHN, TWN, PHL, MEX) • FMEA • sand & saltwater ingress • UV test • fatigue cycle • tensile • field testing • pre-production QAQC • ss investment casting• FEA
PRODUCTION - 55x injection mold tools • rotomold hull integration • alu extrusion/stamp/heat treat/anodize • ss stamp/passivation • CNC machining • laser etching • die cutting • assembly line training • production fixture design