I was the Composites Engineer for the Diverge STR—from prototype through production.
Launched in 2023 and winner of the Design & Innovation Award for Gravel Bikes, the Diverge STR introduced a new kind of suspension: one that isolates the rider using a composite leaf spring and integrated damper. It delivers big-bike comfort at a fraction of the weight.
Bringing it to life meant navigating pandemic disruptions, reinventing legacy test methods, and pushing the limits of what composite structures can do on two wheels.
One of the biggest challenges, placed on my shoulders, was the development of the Frame Post product. I had to design 9 different parts, with identical geometries but different stiffnesses so that we could provide an ideal suspension experience for any size rider.
My primary innovation on this problem was developing a comprehensive design/analysis/manufacturing software tool. With this tool, and an organized configuration system, I could analyze multiple simultaneous layup revisions and output manufacturing cut files for our suppliers with a single button press. I also hand-made >100 prototype parts for this project, developed new test standards and fixtures, and led our over-seas manufacturing team from prototype to production.
I also performed several data analysis tasks for the team, including an analysis of our novel suspension system that turned into a calculator and look-up table for riders so that they could find their perfect Frame Post on the first try.
