Carabiner Production
From Part design Finalization To 500 Production in Six Weeks
Project Highlights
In the Carabiner Project at ARRIS, our goal was to redefine the company standards by delivering 500 carabiners within a never-before-seen 6-week timeframe.
As the R&D Manager and the project lead, I orchestrated a strategy in mechanical design and team coordination, ensuring delivery despite supplier delays and historical manufacturing challenges at Arris. These carabiners were manufactured from long carbon fiber composites, aligned with the principal stress-lines. Each carabiner contains up to 670,000 carbon fibers longitudinally aligned from end-to-end, ensuring maximum strength and stiffness.
This achievement shattered records in lead time, tool longevity, production yield, and quality, with zero production tooling issues.
Huge thanks to the overwhelming response to my requests, 54 of our colleagues supported this project. It stands as a testament to our capability, quality, and culture.
Special thanks to Eric Forrester, Jason Watson, Patrick (Tree) Miller, and Justin Church.
"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