PRODUCTION EXECUSION
Advanced Composite Manufacturing
From design level to 500 shipped units in 6 weeks.
A startup needed 500 shippable carabiners in 6 weeks for a critical company milestone.
The carabiner was chosen because it made the company’s continuous carbon fiber technology visible, tangible, and usable in a single object. No program at that speed had ever been attempted.
The part required precise end-to-end fiber alignment inside a narrow process window, turning a simple-looking object into a full production challenge from day one.
Tooling, fixtures, process development, and line design were driven in parallel from CAD to shipped product.
Tooling ran 24 hours a day for 4 consecutive days with zero failures and zero downtime, a first in the company’s history.
54 people aligned across engineering, manufacturing, and executive leadership to deliver.
500 units shipped on time.
"Sam changed my perspective on what program management should be by his involvement in every step and learning new challenges and addressing them.
Most importantly, he could execute on a timeline that most people thought wasn’t possible.”
Riley Reese, CEO, ARRIS Composites
Continuous Carbon Fiber Alignment is Shown Above