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Design Engineer

Creative & Design

Talented mechanical design engineer, project manager, and proven leader with over a decade of outdoor industry experience; serving in a wide range of roles including product design and engineering, engineering project management, technical sales and service management. 

Passionate about innovative design, creative problem solving, and the outdoors. Formally educated in mechanical engineering, materials science and engineering, mathematics, and computer-aided design and manufacturing.

Fluent in a number of 3D modeling platforms including Solidworks, Creo (Pro/E), Inventor, Rhino, and experienced using AutoCAD, and Mastercam. Adept at 3D digital product rendering using a number of visualization tools including KeyShot and Solidworks Visualize. Skilled in CAD/CAM processes including design for manufacturing (DFM), FMEA, fixture design for CNC operations. Talented fabricator with hands-on engineering approach to designing prototypes, test equipment, experiments, and proofs of concept. Highly comfortable in a shop-floor environment operating manual and CNC mill, lathe, water jet, MIG, TIG, plasma, and other fabrication equipment. 

• Lead innovation, research and development of new products and rider protective equipment
• Develop new materials and processes for impact protection and energy management
• Design, engineer, and fabricate test method and equipment to quantitatively measure cooling performance of helmets
• Travel internationally to meet with vendors and suppliers, oversee production of new products
• Engineer and construct test fixtures to measure stiffness and performance of cycling footwear
• Research and develop innovative solutions to bicycle lighting
• Prototype new product concepts and designs using 3D printers, CNC equipment, shop tools
• Develop test methods and construct DOE for compression testing 3D printed lattice structures
• Use 3D scanners to analyze anatomy, biomechanics, and reverse engineer products
• Write software to analyze and post-process 3D scan data

• Lead design engineer on revolutionary new ski boot design, featuring BOA® Alpine closure system
• Designed, engineered, and tested ski boots, components, and assemblies using Creo (Pro/E), Rhino 3D, Solidworks 
• Managed ski boot laboratory test program, thoroughly tested products for fit, function, quality, durability
• Led product failure investigations, collected, organized, and analyzed warranty and test report data
• Performed hands-on engineering to design and manufacture instrumentation, test fixtures, and tools 
• Traveled to and collaborated with overseas factories on initiatives to improve manufacturing quality and efficiency
• Developed and maintained accurate specifications, tool lists, and development lists
• Performed product training presentations for customer support, sales teams, and retail shop personnel
• Traveled to attend industry trade shows, sales clinics, and on-snow product demonstrations
• Communicated, interfaced with vendors and suppliers to source components, hardware, materials, and tooling 
• Constructed, render photorealistic digital assets using Rhino 3D and KeyShot for marketing purposes
• Designed and applied organic parametric geometry using Grasshopper

Ski Boot Design Engineer

• Designed, engineered, and fabricated innovative tilt-adjustable steering system for Formula 1 style race car
• Performed Finite Element Analysis (FEA) on 3D Solidworks models and assemblies, validated engineering decisions 
• Organized complex full-vehicle Solidworks assembly, containing more than 2,000 3D parts and components
• Led team of 20 mechanical engineering students to design, fabricate, assemble, and test a Formula 1 style race car 
• Implemented cloud-based project management software to manage timeline and workflow of 5 design sub-teams
• Achieved 9-month engineering project goals utilizing critical path analysis, work arounds for challenging problems 
• Instructed 20 engineering students in ASME Y14.5 - 2009 (GD&T), developed team-wide drawing review system 
• Utilized mill, lathe, water jet, TIG welder, and other equipment to fabricate mechanical components for race car

Project Manager & Design Engineer, Formula SAE

• Hired by TEES to consult student competition teams on engineering design process, problem solving methods
• Advised undergraduate and graduate students on design for manufacturing (DFM), correct 3D modeling techniques 
• Designed complex mechanical assemblies for special projects including solar panel array, composite materials rack 
• Taught machine shop safety, proper mill & lathe operations to students in Mechanical Engineering department
• Reverse engineered and fabricated bespoke components to repair machine tools, mills, and lathes

Engineering Design Consultant & Machinist

• Designed 3D parametric models in PTC Creo adhering to plastic design guidelines for injection molding
• Conceptualized 5+ machining fixtures in Inventor and Mastercam for production of 20+ engine components 
• Spearheaded $30K grant proposal to purchase CO2 laser cutter and additional manufacturing equipment
• Developed curriculum, instructional materials, teaching aids for department’s CAD/CAM program
• Programmed and operated HAAS CNC mill and lathe, producing prototypes and small-batch parts

CAD/CAM Curriculum Developer, Architectural & Engineering CAD Department

• Aided in merchandise buying, expanded assortment of bicycles, soft goods, parts and accessories 
• Developed marketing sales and visual merchandising plans, increasing company profits by 15%
• Supervised bicycle service department and trained employees in complex repair techniques

Assistant Store Manager

• Managed bicycle sales and service department of sporting good retail store producing $2.5 million annual sales 
• Developed turnkey multi-discipline bicycle fit program and deployed company-wide across 20+ stores
• Attended Interbike twice, industry conferences, sales trainings to follow new product developments, technologies 
• Trained over 15 employees in sales processes, ski and bicycle repair, and coordinated new-hire orientations
• Supervised ski and snowboard sales, service, and bootfitting over a period of 3 winter seasons
• Designed visual merchandising displays, overhauled backroom organization, optimized inventory storage systems

Bicycle Department Manager

• Serviced fleet of 100+ performance rental bicycles, performed basic repairs, tune-ups, and full overhauls
• Performed suspension and hydraulic disc brake services including upgrades and rebuilds.
• Consulted with customers regarding bicycle performance issues and made repair proposals

Bicycle Mechanic

• Overhauled rental department organization, visual merchandising displays, and rental equipment storage
• Assembled bicycles, tuned and adjusted components, performed pre-sale bike safety inspections
• Engaged with customers to provide service, technical product information, and match products to customer needs

Sales Associate

James O'Connell is a Design Engineer at Specialized Bicycle Components, Inc. in Boulder, Colorado.

James O'Connell

James O'Connell

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