Beginning in 2011, I worked with Quest Composite in China on frame development for Trek. I trained the design engineers developing the laminates and the manufacturing/process engineers producing and troubleshooting them. The first launch was the 2013 model-year Domane.
I worked closely with Quest to start up its frame-development process using the Domane prototype. The work connected a particular product with the engineering capability and manufacturing methods needed to produce it.
I taught composite laminate development, material selection and ply orientation. The work also involved interpreting tests and working through the implications for the design.
This drew on substantial hands-on composite engineering of my own, not only coordination of other people’s work.
I trained the engineers responsible for producing and troubleshooting the designs. My work included new techniques and processes, test interpretation and failure analysis alongside the manufacturing team.
The design and manufacturing discussions concerned the same frame, approached from the requirements of each discipline.
Laminate development, manufacturing methods and test interpretation were connected parts of my work. I worked with both groups on the engineering and on understanding the results from the parts being developed.
I guided the work in writing between visits. On-site, I worked beside the engineers in the development lab and on the factory floor. When the problem needed direct investigation at the manufacturer, I went to China to work through it with the team.
The engagement extended beyond a design handoff. I continued to work on composite development, manufacturing techniques and technical training after the first product launch.
On my programs, I made material, ply-orientation and final-weight decisions. I approved test standards and results and quality-control checks and held the technical production go/no-go responsibility.
The first Domane launch was a concrete milestone in the manufacturing relationship. The technical work with Quest continued beyond it.