SHREDmill: Designing for Manufacturability

The Challenge

SHREDmill is a unique training “treadmill” that is designed to maximize an athlete’s speed potential. The team at SHREDmill came to Hatch with an existing product design that needed to be manufactured. Although the proof of concept prototype was able to prove the initial idea, it was not yet ready to be mass produced. The device was heavy, expensive, and inconsistent in its design. Additionally, the client wanted to incorporate an IoT sensor into the product to enable connectivity with a new app.

Mechanical Engineering
App Development
Prototyping
Design for Manufacturing

Development

The Hatch team started working with the existing CAD data to review design processes and manufacturability. The team did a gap analysis study based on customer feedback of the current design. Using this information, the Hatch team redesigned the components in a streamlined way that also reduced the BOM and shipping costs. Lastly, the team improved the drawings in such a way that they communicated critical information to Hatch’s partnered vendors.

SHREDmill Design for Manufacturing
SHREDmill Design for Manufacturing
SHREDmill Design for Manufacturing
SHREDmill Design for Manufacturing
SHREDmill Design for Manufacturing
SHREDmill Design for Manufacturing

In parallel, the team incorporated an IoT sensor into the device that connects with a new mobile app, designed by Hatch. This enables SHREDmill users to record workouts and view their progress and results via the app.

Prototyping

In order to prepare for manufacturing SHREDmill at Hatch CM, the team built prototypes for design verification. By prototyping a small quantity, the team was able to assess the quality of the components ahead of manufacturing. Using Hatch’s existing relationships with trusted vendors, the team improved the parts to ensure a high quality manufactured product. This also allowed line workers to be trained ahead of large scale manufacturing.

SHREDmill Design for ManufacturingSHREDmill Design for Manufacturing
SHREDmill Design for ManufacturingSHREDmill Design for Manufacturing

“Hatch’s pragmatic approach to the DFM and design verification process led to the absolute best manufacturable version of our product.”

CEO | SHREDmill

Manufacturing

By using both Hatch’s in-house design and manufacturing teams, the transition to building the product was seamless. The engineers who worked on the product designs also assisted with creating a smooth final-assembly manufacturing line. The Hatch team procured material and managed inventory using cost effective oversea partners. Once the parts were delivered to Hatch, the previously trained line workers were able to expertly assemble the units. Finally, the quality control team ensured the delivery of a high quality, American manufactured product.

SHREDmill Design for Manufacturing

“The SHREDmill has helped me tremendously. Just from the technique of having to run correctly, you can see how people’s stride length and power improve.”

Anquan Boldin | Former NFL Player

SHREDmill has been highly acclaimed by elite athletes ranging from the NFL to MMA and more.

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