Guerrilla Gear
Product Design & Manufacturing Lead
Led DFM/DFAM for a modular weight-stack system, achieving a 2.5x FoS via FEA and material optimization. Orchestrated a distributed manufacturing network reducing per-unit cost by 13%. Transitioned V1 thermoplastic innovation to V2 precision-machined variant, scaling fulfillment for six-figure revenue growth.
Key Contributions
META Pin
The Challenge
Ground-up mechanical overhaul to a "Zero-Fail" commercial system with an interchangeable 8mm/10mm rod system.
The Approach
Transitioned to CNC-machined 6061-T6 Aluminum via sourced partners in the Xometry network. Utilized H7/g6 sliding fits and a concentric adapter sleeve system to ensure precision modularity. Coordinated the technical hand-off and QC inspection for all mission-critical dimensions.
The Impact
Verified a 2.5x Factor of Safety for dynamic peak loads (450lb+). Reduced field failure rates to 0% while supporting six-figure product growth through technical reliability and interchangeable pin modularity.
Thermo Pin
The Challenge
Identify and solve a gap for a modular weight-loading pin with zero upfront tooling cost. The goal was to validate product-market fit using agile manufacturing before committing to metal production.
The Approach
Engineered a modular "Base + Extender" architecture. Optimized Design for Additive Manufacturing (DFAM) print orientations for shear-force resistance. Sourced and coordinated with Slant 3D to utilize their distributed print farm, scaling to thousands of units.
The Impact
Established a new product category and enabled six-figure product growth via agile thermoplastic production. Dynamic stress testing revealed elastic deformation limits, providing the baseline requirements for the V2 metal overhaul.