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

Brothers Jesse, Luke, and Mason Hambly were college students when they had the idea for a healthy thirst quencher that presses fruit juice directly into water. The trio of brothers, who deferred college a couple years to try to make it on the professional snowboarding circuit, noticed that their college classmates were infusing water using the same inefficient method of submerging fruit in infuser bottles. After testing infuser bottles, the brothers noted that while they helped them to drink more water, the infused water lacked flavor. In fact, they learned that instead of releasing fruit juice into the water, infuser bottles did the exact opposite: The fruit absorbed water, bloated, and created a mess that had to be cleaned out later, without ever releasing the flavorful juice inside.

That experience led to the idea for a water bottle with a twist dial on top, which operates a press inside. By turning the dial on top, users press the juice from fruit and its flavor directly into the water. Luke, who was studying design engineering at Conestoga College, took on the concept of pressed water as his senior design project, and the Pressa Bottle was born.
“While I was an engineering student at Conestoga College, I learned how to use SOLIDWORKS® 3D design software,” Luke recalls. “I found SOLIDWORKS to be very user-friendly—with lots of YouTube lessons and tutorials available online—and I was passionate about learning how to use it well. At the same time, my brothers and I were kicking around the idea for pressed water, so I created the initial concept for the Pressa Bottle as my senior design project. Once the design was complete, I purchased a 3D printer because I knew I had to make it.”

Luke Hambly’s initial design for the Pressa Bottle—created with SOLIDWORKS Education Edition software—was so innovative and carried so much commercial potential that upon graduation, he enlisted the help of his brothers. Jesse manages marketing and ecommerce, and Mason is a filmmaker who creates video content for the company. The brothers then set out to transform a college design project into an innovative product supporting a viable manufacturing business, with SOLIDWORKS for Entrepreneurs software as their product development solution.

College Design Project Leads to Patent

With a workable product idea, the Hambly brothers were shrewd enough to recognize that other companies might try to steal or copy their pressed-water bottle idea. So their first order of business was applying for a patent on the Pressa Bottle to protect their intellectual property (IP).

Pressa bottle demo

“Although I designed the Pressa Bottle for a college course, I and my brothers owned the IP and immediately filed for the patent, which we have since received,” Luke recalls. “We had a viable product design, an excellent tool in SOLIDWORKS for refining the design prior to production, and agreement that it was time to take a risk. The next step was finding a way to make it into a business.”

From Kickstarter to “Dragon’s Den”

To acquire funding, the three brothers put together a Kickstarter video using 3D-printed prototypes, with filmmaker Mason taking the lead. “We had to confirm that it wasn’t just friends and family that thought this was a potentially lucrative product idea,” Luke explains. “The Kickstarter campaign resulted in $40,000 in funding as pre-orders in 2015 and allowed us to begin working with a moldmaker to create prototype molds and begin optimizing the design in SOLIDWORKS for production.”

After shipping the Kickstarter pre-orders, the three brothers visited the “Dragon’s Den”, the Canadian version of the American television show “Shark Tank”, to see if they could raise additional funding from the panel of six venture capitalists. While four of the “dragons” made offers, the brothers accepted Jim Treliving’s offer of $150,000 for 25 percent of the company, with the remaining 75 percent split evenly among the brothers.

Ramping Up Production and Sales

With the “Dragon’s Den” funding, the Hambly brothers set out expanding their product offering from one Pressa Bottle model (plastic) to three (glass, metal, and plastic); working with their moldmaker to improve the Pressa Bottle design; and ramping up their production and sales efforts. “SOLIDWORKS enabled us to communicate effectively with our moldmaker to tweak the design and make adjustments in real time, such as doing a better job hiding parting lines,” Luke notes.

The company has continued to grow since the “Dragon’s Den” funding, with a steady increase in sales. “We’ve seen sales growth month over month with sales projected to top 200,000 bottles in 2019,” Luke says. “With the success that we’ve had with the Pressa Bottle and SOLIDWORKS for Entrepreneurs product development tools, we’re excited to develop additional future products.”

Challenge:

Transform an innovative pressed-fruit water bottle design that was created for a college design project into a viable manufacturing company.

Solution:

Implement SOLIDWORKS for Entrepreneurs product development software.

Benefits:

• Realized projected sales of 200,000 bottles in 2019
• Adapted initial product design into three products
• Leveraged design and 3D-printed materials to launch Kickstarter campaign
• Secured patent for pressed-fruit water bottle

“SOLIDWORKS enabled us to communicate effectively with our moldmaker to tweak the design and make adjustments in real time, such as doing a better job hiding parting lines.”

— Luke Hambly, Co-Founder

Customization usually means longer lead times, but landscape architects and site contractors can rarely afford to wait. Implementing DriveWorks, with the support of TriMech, has helped Maglin move to manufacturing – and to market – faster.

Maglin uses a DriveWorks-powered configure-price-quote (CPQ) system for three of its furniture lines – Lexicon, Ogden, and Pixel. Each line is built to order and available in different sizes, colours, materials, and layouts – there are thousands of possible configurations. In the past, getting from desired specs to approved drawings took at least two weeks; today, the entire process can be done in one online configuration session.

Maglin Product Builder

Customer approval on the spot

Aaron Dawson is Director of Manufacturing for Maglin. To demonstrate the impact of changing from a manual process to using DriveWorks, he points to the Ogden modular product line.

“We offer thousands of various bench radii, making it a custom product always built to order. To avoid costly errors and wasted time and materials, customer approval of the layout drawings is paramount.”

Before implementing DriveWorks, a sales rep would talk to the customer and record the specs required, then request the drawing. An engineer would create the drawing and send it to the customer for approval. Once approved, production would begin.

Even if there were no changes, working through a drawing approval process would take about two weeks. If the customer wanted changes, that timeline could double.

Using DriveWorks, this process has been eliminated. A sales rep can automatically create the drawings based on the chosen configuration or Maglin can give the landscape architect access to the system to create his or her own design and drawings.

Maglin Product Builder – Configure Lexicon

One session provides pricing and drawings

At the beginning of a CPQ session, the sales rep or customer chooses the specs for each element – shape, dimensions, colour etc. The system continually updates in real time, including pricing, as they try different options. When the design session is over, they have drawings, a model to insert into their site drawings, and a quotation. DriveWorks is linked to Maglin’s freight partner’s database, so even the shipping cost is generated automatically – the system knows the size, weight, and number of packages.

“The engineering team is not involved in this process at all,” Aaron says. “They are entirely dedicated to the production process and new product development.”

Automation means more time to focus on new projects

Sometimes, when there is talk of automation, people fear the change or worry about the impact on their role. Aaron says DriveWorks has removed the backlog of projects in the sales process and has freed up designers to use their creativity to design new products.

“Automation tools remove day-to-day repetitive tasks. Our designers no longer have to spend time tweaking the furniture configuration because the software does that. Our designers were on board from the start. They have totally embraced it.”

Aaron also points out that because the sales process moves faster, overall business revenue is increasing. He can add more designers to the team. The sales team has been freed from their backlog as well, and can focus on creating and strengthening relationships with customers, which is critically important to Maglin.

“There is no lack of opportunity out there,” Aaron says. “And our sales people now have more time to maximize the use of our CRM. They can see who has been working on layouts online and give people a call to talk about their needs. We want new clients and new projects – that’s the most valuable use of their time.”

Skate Park Configuration – Maglin Ogden

DriveWorks representatives listen to feedback

Maglin’s original reason for implementing the DriveWorks CPQ system was to get to manufacturing quicker to reduce the cash conversion cycle. As they gained experience, they started wondering, “Can the software do this?” and “What if we could make the system work like that?”

“We’ve been pushing the envelope,” Aaron says. “We continually challenge the people at TriMech and at DriveWorks. Nobody at TriMech ever says ‘no, that can’t be done’ – they are always open to trying new things. And DriveWorks representatives have listened to my feedback and have addressed my concerns. We are working directly with the developer to influence their product. That’s a win-win for us and for DriveWorks.”

TriMech is part of the team

TriMech helped Maglin design their initial online system and provided guidance on everything from hardware selection to testing, troubleshooting, and optimizing performance.

“If another company is finding DriveWorks challenging, it’s because they don’t have a technical partner like TriMech,” Aaron says. “We couldn’t have gone as far as we have on our own. Lee from TriMech is part of our team and walks freely around our plant.”

Maglin will continue to work closely with TriMech and DriveWorks to make further progress. Aaron says it’s a continual learning process for everyone and has appreciated that TriMech has pointed him to funding opportunities for resources and training; Maglin has been able to secure grants to support their investment in DriveWorks.

“TriMech helps us understand what’s coming, including the new technology that will make a difference for us and how they can help. Our CEO Ian McAskile said that DriveWorks, with Javelin’s mentoring, has been a game changer for us as we continue to be a leader in our industry.”

DriveWorks Benefits for Maglin:

• DriveWorks gives sales reps and landscape architects an easy-to-use online system for configuring modular site furniture, generating pricing, and creating drawings, continually updating in real time
• Maglin’s typical two-week sales process, including customer approval of drawings, has been eliminated
• Engineers are free to develop new products; they are no longer tied up making and tracking small tweaks to designs
• Using CPQ automation, Maglin can meet customer demand for speed while continuing to provide customization and quality; they are also winning more projects by delivering quotations and drawings quickly
• Effects are company-wide: overall revenue has increased; sales reps have more time to spend on relationship building with new and existing customers; the marketing team is able to promote the benefits of the DriveWorks system
• Working directly with both TriMech and DriveWorks, Maglin has been mentored and supported and is contributing to future releases of the software that will benefit everyone

“Automation tools remove day-to-day repetitive tasks. Our designers no longer have to spend time tweaking the furniture configuration because the software does that. Our designers were on board from the start. They have totally embraced it.”

– Aaron Dawson, Director of Manufacturing

Maglin’s finished projects

Based in Waterloo, Ontario, Aeryon design Small Unmanned Aerial Systems (sUAS) for a range of applications around the world.

Aeryon Labs Glen Johannesson

Aeryon had its start in 2007, with the release of the Scout in 2009. The founders’ original idea was to develop a tool for collecting aerial imagery. The commercial market wasn’t quite ready to invest, but the military was, and they were the first to purchase the technology. By 2010, police services had begun to use the drones in traffic collision reconstruction. Taking photographs from the air helps with accurate measurements and capturing visuals like skid marks. Officers report that investigations that used to take two hours now take only 15 minutes, allowing them to clear scenes quickly and avoid the economic and social impact of road closures.

Designing for flight

Glen explains that designing a drone is about opposing needs – it has to be strong, but lightweight enough to fly. And of course, you have to be able to make it before you can make it fly.

SOLIDWORKS® is the 3D design tool of choice for the engineers at Aeryon. They choose TriMech to provide and support the software, and ever since a smooth initial implementation, have expanded their SOLIDWORKS user base.

The benefit of clearly seeing designs in very early stages translates easily to savings, both in time and dollars.

“It can cost up to $15,000 to make a mold, so if we have to modify the design, it’s expensive,” Glen says. We used to cross our fingers a lot. If we can catch an issue early in SOLIDWORKS, and save that money, the software pays for itself in one situation.”

Not only did reducing the number of molds save money, particularly important in the early days when sales were just beginning to ramp up – but Glen was also able to combine parts, generating more savings and optimizing the aircraft’s weight and performance, and passing those savings and performance benefits on to the customer.

Picture of Elora Quarry from the sUAS

Lightweight and custom

The drone design is a complex, integrated system of hardware and software, designed to be easy for the pilot to operate using a tablet controller. It is built so that the propellers and legs can be transported attached to the aircraft or assembled in the field without tools, and if it takes a hard landing, these components can be easily snapped back on.

Aeryon Sky Ranger Package

Aeryon sUAS are in the five-pound range, with a bit of variance based on the weight of the camera payload, which is 10% of the craft’s total weight. Commercial customers operating in Canada and the U.S. are certified to fly based on certain weight classes so designing to keep it lean and light is critical.

Glen and his colleagues design all the components in SOLIDWORKS and assemble and test them in house. Aeryon’s partners make the molds and components.

Customization is key. Different customers have different requirements for the unit, from thermal sensors, to zoom lenses, to air quality measurement equipment, to the highest levels of encryption for security. Aeryon aircraft fly in 35 countries around the world, so other customizations ensure safe operations and compliance to airspace and government regulations.

Customer-driven drone design

Glen says working at the forefront of a new industry means working closely with users and potential users to advance the product and meet the current and future needs of customers. In the first year or two especially, customers were curious – and hopeful – about the applications.

“In the beginning, we needed feedback to help the customer be successful. Customers would say, ‘can you make it do this?’ and often we hadn’t even thought of ‘that’ yet. Our customers have helped to determine the functionality.”

It’s also been important for Aeryon designers to react quickly to customer problems in the field. One customer needed to fly close to high-voltage power lines but was unable to because of the sensitivity of the aircraft’s magnetic sensor. The team worked all weekend to redesign a new version of the drone that would briefly ignore the interference and the customer was able to get the job done.

Powerline Inspection

“They couldn’t believe we reacted so quickly, in just a few days,” Glen explains. “We used SOLIDWORKS to quickly modify the design to accommodate those unique needs.”

Glen also appreciates being able to show people detailed renderings on screen. Even if you’re not a mechanical engineer, you can easily see what the aircraft system is going to look like. Aeryon has even used rotating SOLIDWORKS images in a corporate video to help people understand the behind-the-scenes drone design process.

SOLIDWORKS renderings

“I can’t imagine doing this without SOLIDWORKS,” Glen says. “I used to start a design with pen and paper. Now, with the ease of sketching, assembling, and building in SOLIDWORKS, I just dive right in, even at the concept level.”

To learn more about Aeryon’s drone design, visit them online at aeryon.com.