Boyd Cycling & Time Bicycles Engineering Internship
Advanced Carbon Fiber Manufacturing & Quality Assurance
Engineering internship at Boyd Cycling and Time Bicycles, focusing on RTM process optimization, custom impact testing equipment development, and international technology transfer at CU-ICAR.
Key Engineering Achievements
RTM Process Optimization
Eradicated dry zones and standardized resin distribution across carbon rim production
Custom Impact Testing
Built custom wheel-impact rig validating 40J UCI standards with precision
International Tech Transfer
Accelerated Time Bicycles' U.S.A. rollout through European protocol implementation
Project Overview
A comprehensive engineering internship encompassing three major initiatives: RTM process optimization, custom testing equipment development, and international technology transfer.
RTM Process Optimization
Enhanced carbon-rim fabrication by overhauling mold geometry and machine calibration
The Challenge
Boyd Cycling's RTM (Resin Transfer Molding) process was experiencing inconsistent resin distribution, leading to dry zones in carbon rims and variable product quality. Manufacturing efficiency was compromised by unpredictable fabrication outcomes.
Solution Approach
Conducted comprehensive analysis of existing mold geometry and machine calibration parameters. Identified inconsistent resin distribution patterns causing dry zones in carbon rim production. Redesigned mold flow patterns and optimized injection parameters to achieve uniform distribution.
Results
Eradicated dry zones and standardized resin distribution across all carbon rim production. Significantly improved manufacturing consistency and product quality standards throughout the fabrication process.
Key Achievements
Custom Impact Testing Equipment
Conceived and built a custom wheel-impact rig validating rim durability to 40J UCI standards
The Challenge
Boyd Cycling needed reliable, consistent impact testing capabilities to validate carbon rim durability according to UCI standards. Existing commercial testing equipment was cost-prohibitive and lacked customization for specific rim geometries.
Solution Approach
Designed and fabricated a custom testing apparatus utilizing electromagnetic release mechanisms for consistent impact delivery. Implemented precision control systems using winch and electromagnetic stopper systems to ensure repeatable testing according to UCI standards.
Results
Successfully validated rim durability to 40J UCI standards with precision and repeatability. Provided cost-effective validation solution compared to commercial alternatives while maintaining professional testing standards.
Technical Specifications
International Technology Transfer
Transferred European carbon-injection protocols to CU-ICAR, accelerating Time Bicycles' U.S.A. rollout
The Challenge
Time Bicycles needed to establish U.S. manufacturing capabilities at CU-ICAR while maintaining the quality and precision of their European composite injection processes. This required adapting established protocols to new facilities and equipment.
Solution Approach
Collaborated with European engineering teams to adapt established carbon-injection protocols for U.S. manufacturing operations. Successfully integrated Time Bicycles' proven processes into CU-ICAR facilities while maintaining quality standards and production efficiency.
Results
Accelerated Time Bicycles' U.S.A. rollout by implementing proven European manufacturing techniques at CU-ICAR. Demonstrated cross-cultural technical adaptability and successfully maintained quality standards across international facilities.
Key Contributions
Get In Touch
Open to discussing engineering opportunities, collaborations, and innovative projects.