In 1996, a snowboarding injury caused Christian to become paralyzed from the waist down. As an athlete, machinist, and creative and determined problem solver, he started designing equipment to help make life better for himself and others facing mobility challenges. One result is Bowhead, which designs and manufactures off-road adaptive e-bikes and has its home base in Calgary, Alberta, Canada.

Bowhead Shop Floor

Sanket Patil is a mechanical designer and engineer-in-training at Bowhead. He started in the business as a volunteer, passionate about delivering an adaptive biking experience and ready to contribute his skills. Beginning in 2020, he joined the company as a full-time designer, troubleshooting issues found during field testing and improving designs.

Bowhead e-bikes are engineered to order to suit a person’s level of mobility and specific needs and wants. Sanket explained that the whole purpose is to accommodate each unique user, so the design process must follow suit.

Bowhead RX at Trout Lake

“A customer chooses options depending on variables such as their foot size, or the type of seat they prefer, or whether they have use of their hands or back muscles. This customization means we need to manage hundreds of parts, complex assemblies, and hundreds of thousands of possible combinations.”

Better data management became a priority

Bowhead’s first e-bike model was REACH. When they moved on to the RX model, Sanket said they suddenly had a lot of data that couldn’t be managed in a folder system any longer.

In 2020, Sanket was the only one working on CAD regularly. A folder system worked fine at first, but it soon became difficult and time consuming to implement and control revisions. He also lacked detailed design history, and creating multiple files was causing a storage capacity issue.

He had some experience working with product data management (PDM) solutions, but he was wary of the upfront investment that would be required and knew that Bowhead would also need to outsource customization and implementation.

“We had also added engineers working on our designs remotely,” he said. “We had to quickly implement a PDM solution that was flexible and easily scalable as our company continued to grow.”

The path to choosing 3DEXPERIENCE

Bowhead was already involved with the Dassault Systèmes SOLIDWORKS for Entrepreneurs program, so they approached Dassault to talk about their evolving needs and get advice. Dassault introduced Bowhead to 3DEXPERIENCE (3DX) and offered a chance to try the platform and discover its capabilities.

Sanket was impressed. He said 3DEXPERIENCE, and the ENOVIA data management tool in particular, allows his team to manage CAD efficiently and collaborate.

Managing CAD Data in 3DEXPERIENCE

“We run the platform practically out of the box and since it’s cloud-based, we don’t have to worry about maintaining servers or hiring an IT specialist. These are crucial aspects for a start-up like ours.”

Bowhead has since grown to have four engineers on site in Canada and two contractors who connect to 3DX from India.

“It’s easy to involve all the engineers in product development,” Sanket said. “We all work with the latest revision. I can easily redline a drawing, send a change order, and later approve that change. And as the company matures, we are expanding to managing other parts of our operation.”

Beyond CAD data

Since implementing 3DEXPERIENCE, Bowhead has expanded beyond using the original design-based features into project planning and change management features.

ENOVIA Data Management

They have also started using some product lifestyle management tools the platform offers, such as doing full product BOMs for their e-bike projects, which include non-engineering items like harnesses and labels.

“We were in the R&D phase of the RX when we got 3DEXPERIENCE and it really set us up for success in manufacturing. The careful tracking makes the design process transparent to the end user. Every piece of a product’s history is searchable and traceable.”

Onboarding and support from Javelin

Implementing a new technology platform while developing a new bike might have been daunting but Sanket says the software was user friendly and easy to learn. And Javelin – A TriMech Company, which provides and supports SOLIDWORKS and Dassault Systèmes solutions, made sure he and his team were trained and positioned for success.

“Javelin guided us through the setup and resolved queries as they arose. Their service is impeccable and response times are amazing. With their help, we didn’t have a single day of downtime, which is absolutely essential for us to meet our deadlines.”

Javelin has a detailed process for onboarding clients to get them operational and feeling confident quickly. As the main admin, Sanket did a training session over three half days; others on his team joined him for the last day.

He explained that he knew the system could do certain things, but he didn’t know how, and that these were the kinds of questions he posed to Javelin.

“One thing I struggled with was the part-numbering system. Ours was already in place and I didn’t want to change it. Javelin understood the ins and outs of 3DEXPERIENCE and created a process workaround involving file naming, which made our existing system compatible.”

Sanket also noted that he’s glad Javelin and 3DEXPERIENCE are at the helm of Bowhead’s data management and will take care of the increasing complexity they’ll face as the company grows.

“There is no stopping us now – we will continue to innovate and bring smiles to our customers’ faces.”

Bowhead is online at bowheadcorp.com.

Bowhead REACH – adaptive mountain bike

Why is 3DEXPERIENCE proving successful for Bowhead?

• 3DEXPERIENCE Works supplements their existing desktop SOLIDWORKS tools with powerful cloud-based data and product lifecycle management.
• They now have one cohesive system accessible from any device.
• 3DEXPERIENCE Works is ready to handle more (and new types of) users and complexity as the company grows.
• No major upfront capital investment was required, well suited to a start-up like theirs.
• Bowhead has a trusted relationship with their technology partner Javelin.

From job sites to camp sites, farms to fishing holes, DECKED products allow pickup truck owners to improve storage capacity, protection from weather, organization, and ergonomics. The idea is to put more in your truck and retrieve all of it without stretching over the bed rail or crawling over everything you’re carrying.

DECKED products allow pickup truck owners to improve storage capacity, protection from weather, organization, and ergonomics

In business for about nine years, DECKED continues to operate with a dynamic team and start-up culture. In earlier years, they focused on designing and building truck bed drawer systems and accessories; today, they are expanding product offerings, such as a new toolbox that sits behind the cab and includes an integrated ladder.

DECKED has grown to a team of 70 people and is on track to sell 50,000 drawer systems this year. Design, sales, and marketing are in Ketchum, Idaho and manufacturing is in Defiance, Ohio.

Calvin Allan is Principal – Product Development for DECKED. He said a midwestern, Idaho work ethic is built into the company’s DNA.

“We’re proud of our attention to detail and we must get it absolutely right. We could stop at good enough, but we don’t. We always make it stronger and better than we have to. Our company prioritizes that.”

Solving the slowdowns

As the DECKED design team expanded, they were wasting time opening and rebuilding large assemblies. The OEMs supply massive, detailed models of their truck beds. Add that complexity to DECKED’s own complicated models, and integration and manipulation of assemblies wasn’t happening fast enough.

“Customization is our magic and the key to our profitability,” Calvin said. “Our configurable SOLIDWORKS models need to be updated quickly. I knew we needed to go deeper into how SOLIDWORKS is running and learn how to optimize accordingly.”

To investigate, TriMech did a Large Assembly Performance Audit and a PDM Health Check and Audit.

They recommended that DECKED take advantage of TriMech’s Large Assembly Productivity Service, to teach Calvin and his team how the software operates “under the hood” during opening and rebuilding phases, how to identify what causes slowdowns, and how to solve those problems. It was also important for users to learn best practices for creating fast and clean large assemblies.

“TriMech didn’t just do the work,” Calvin explained. “They taught us what levers they pull to make a difference. We learned the implications of how we were doing CAD, such as how display states and section views were affecting our work. Unused elements and suppressed components were creating errors and bloated models.”

Calvin’s team learned that when they don’t need great detail, working with resolved (unsuppressed) assembly components is unnecessary.

“When vendor models come in, there is excessive detail. Now we know that if we don’t need to see a detailed thread pattern, we get rid of it. We didn’t know we had so much control over opening individual parts.”

The team now works faster than they ever have before.

“I’m not exaggerating when I say our opening times are 10 times faster. Files that took 30 minutes to open now open in a few minutes and files that took a few minutes now open in seconds.”

Custom, relevant training

TriMech delivered team training remotely from Canada and it was recorded for anyone who couldn’t attend live (or for future new hires). Even Calvin, an advanced user, learned “golden” tips during TriMech’s training sessions.

“The training was custom to our work, geared toward what we were seeing every day. They didn’t use canned examples. You could spend years doing something one way, never knowing there’s a better way.”

Work faster and reduce errors using PDM features

Calvin also noted that TriMech’s PDM Health Check and Audit revealed areas for improvement. Again, the DECKED PDM system was organized well enough for one person but not efficient when multiple users contribute to the same files.

“TriMech didn’t come in with a prescribed recipe. They said, ‘show us what you’re doing.’ Their audit report recommended improvements, then their services team built them right in front of us.”

Overall, that meant modifying the existing workflow to suit current business processes. DECKED now has a faster, better file search function, automated processes (such as file conversion) using SOLIDWORKS PDM Tasks, and email notifications to speed up drawing review and approval.

“We were using PDM for file storage, like you would use Google Drive,” Calvin said. “We weren’t using it to manage our workflow and we had no gating. Now, our file structure is efficient. It’s fast and easy to find files, see if they are checked out, and understand what stage they’re at. We can tag files to bypass review or demand review. We can see if files have been to the vendor or parts have been released.”

With PDM use elevated, more people at DECKED are beginning to understand how it can be a meaningful tool across the company.

Devote the time to learning

DECKED started benefiting from their investment in training and services quickly, putting new methods into practice right away.

“There will always be emergencies competing for your attention,” Calvin said. “You have to devote the time to learning to be better off in the long term. And TriMech has been a well-oiled machine. They have what I need – the people and processes for deployment and follow up.”

DECKED is online at decked.com.

Damon has patented a 360-degree AI-enhanced Advanced Warning System for Motorcycles called COPILOT™ and designed and built the world’s first shape-shifting electric motorcycle.

The safety system locks onto dozens of objects around the motorcycle and alerts the rider to oncoming threats using LEDs and vibration in the handlebars. The embedded crash detection sensors also collect rider, traffic, and vehicle data and send that information to the cloud. This means that Damon’s system learns from every rider and every situation.

The electronically adjustable ergonomics system unique to the Damon design is called SHIFT™ and is made up of four auto-adjustable points: seat, handlebars, foot pegs, and windscreen. Incredibly, the bike shifts from sport to touring to upright/city positions.

Damon Motorcycles – Halo Bike designed in SOLIDWORKS

Meeting design challenges using SOLIDWORKS

Damon’s strengths are rooted in technology but their mechanical engineering team gets the credit for building their proof-of-concept Halo bike.

They used a combination of 3D scanning, SOLIDWORKS desktop software, and 3D printing to create the unique and tricky components that would allow the bike to transform.

Product Design Manager Raymond Leung said a bike like the Halo had never been built before and it was challenging work.

“We had to build a safe, ridable prototype that would not only have a pleasing appearance but also features that transform. Parts need to morph safely and smoothly without interference.”

Raymond arranged for the basic features of a motorcycle to be laser scanned, then imported the scanned data into SOLIDWORKS. Reverse engineering gave him the base for creating the necessary appearance, as well as for designing mechanical parts.

Raymond said he trusts SOLIDWORKS to allow for multiple designers and engineers to work on a single file, and to handle large assemblies well. His team members often have to work in parallel and his models have more than 500 components. Those models come together to create the main assembly.

Advice on working with large assemblies is one of the ways Raymond has received help from TriMech. He has been using SOLIDWORKS for many years but occasionally relies on TriMech’s depth of expertise.

“TriMech gets back to me immediately with advice about how to solve any problem I run into. It’s convenient for me to visit them in person in downtown Vancouver to show them a problem and get timely help. They also have expertise in working with scanned data and in 3D printing so they bring a lot to our conversations.”

Next up, Raymond will be investigating SOLIDWORKS Simulation to enhance his ability to virtually test part performance, as well as solutions to improve data storage and supply chain management. Damon will also use SOLIDWORKS to design the next generation of the ergonomic system – one that conforms to the unique characteristics of an individual rider for maximum customization and comfort.

Changing the industry and rider experience

Head of Product Marketing Amber Spencer said the Damon team is proud of their progress to date.

“We’ve done so much in so little time, including taking the bike on tour. Our founder and CEO Jay Giraud presented a TechCrunch session and we’ve given media and motorcycle manufacturers a chance to try the bike. Everyone has been blown away. Seeing the reaction on people’s faces, when they ride the bike we created, has been very rewarding.”

Damon’s main purpose is to cause a shift in the industry. Motorcycles are often seen as unsafe, intimidating, and hard to ride.

“We want to see more people enjoying motorcycles,” Amber said. “With our background and tech expertise, we’re able to increase a rider’s safety and comfort exponentially. As we move forward into the future, we will continue to find ways to make the riding experience better.”

Damon’s future also includes securing further investment and business partners, and spreading the word about their innovations to individual riders. Amber said any motorcyclist who is interested can get on a list to test ride the bike and give essential feedback.

“We definitely want people to visit our website and learn more about us. And when you put your name on our beta list, you’ll have an opportunity to test ride and pre-order the Halo bike.”

For more information, please visit the Damon website.

Damon Motorcycles Team, Vancouver BC

Richard M. Grant, company founder and president, has built significant expertise over the past 25 years in analyzing structures that must withstand substantial forces—including his work as the principal structural analyst on the Canadian Navy Maritime Coastal Defense Vessel, a sophisticated minesweeper. When he founded Grantec, Grant realized he would need a robust, flexible, and affordable set of analysis tools in order to meet his clients’ diverse engineering challenges consistently, efficiently, and cost-effectively.

“I had used several finite element analysis (FEA) packages throughout my career, including ALGOR®, ANSYS®, NASTRAN®, and SOLIDWORKS® Simulation,” Grant explains. “When I selected an analysis system for my consulting company, the decision was easy because I had assessed different analysis packages and made recommendations on the best system for advanced structural studies for my former employers. I had always considered SOLIDWORKS Simulation my preferred FEA tool because it is the most versatile, and represents the best value. With SOLIDWORKS 3D CAD software, I have the full range of capabilities I need to conduct sophisticated nonlinear analysis at an affordable price.”

Grantec selected SOLIDWORKS Simulation Premium, including SOLIDWORKS Motion, to support its advanced structural analysis needs because of the software’s ease of use, complete set of capabilities, integration with SOLIDWORKS Premium CAD software, and value.

“SOLIDWORKS Simulation is a very robust, well-established code that provides more bang for the buck than other analysis systems; using SOLIDWORKS software is a more efficient approach because we can handle more complex geometries. This allows us to conduct advanced analyses faster and more cost-effectively.”

From offshore structures to high-level research

The productivity gains Grantec has realized using SOLIDWORKS Simulation are significant. The software has benefited projects ranging from large, flexible marine riser systems used for offshore drilling, which must withstand the forces generated by ocean waves reaching 22 meters and higher, to large research pressure vessels, which must withstand seismic shocks.

“We used SOLIDWORKS software analysis tools on the design of the Trident Enhancement Vacuum Chamber for the laser facility at Los Alamos National Laboratory,” Grant explains. “The chamber provides confinement for weapons and physics research. The Fast Finite Element solver was a big advantage in analyzing the stability of the chamber under external loads. We performed seismic, thermal, deflection, and nonlinear buckling analyses to assure a high level of integrity for the chamber.

“We conducted similar analysis and design efforts, including fatigue analysis, for a large research vacuum chamber used in conjunction with the US Department of Energy’s Neutron Acceleration Project,” Grant adds.

“The combination of modeling and fast-solving capabilities in SOLIDWORKS software enables us to do more analyses because we can change a model, remesh, and re-analyze very efficiently. This approach boosts our productivity by as much as a factor of 40, and allows us to provide a higher level of service in a shorter period of time.”

Gap, contact elements advance assembly analysis for the Coastal Defense Vessel

Grantec makes heavy use of the gap and contact elements in SOLIDWORKS software because the vast majority of the consultancy’s work requires advanced analysis of assemblies. “It is very rare to get an assignment that does not require assembly analysis,” Grant notes. “Essentially, we could not conduct the types of analysis we do without the assembly analysis capabilities found in SOLIDWORKS software.”

TEXCC Chamber Panel Stress

The firm relied heavily on SOLIDWORKS software gap and contact elements to conduct detailed assessments of the response of a range of specialized welds on the Trident Enhancement Vacuum Chamber for Los Alamos National Laboratory.

Greater data compatibility, better communication tools

In addition to providing Grantec with a full range of analysis capabilities, SOLIDWORKS CAD software expands the firm’s ability to handle various forms of compatible design data, and improves its ability to communicate analysis results to customers.
“Most of the people we deal with are using SOLIDWORKS CAD software, and come to us for advanced SOLIDWORKS software analysis capabilities,” Grant points out. “Our solution is also compatible with other design platforms because we can import all of the leading CAD formats into SOLIDWORKS Simulation.

“We use SOLIDWORKS eDrawings® to communicate analysis results to our customers,” he adds. “On a recent project for a large 500-ton desalinization unit, we sent our SOLIDWORKS Simulation analysis results to our client in Saudi Arabia via email as eDrawings files, which was very effective.”