As a mechanical design engineering intern at Archer Components, I was tasked with designing a successor to the currently available D1x electronic shifter, which shifts the gears on a bike by pulling a cable based on input from a wireless remote

Goals

• Improve water resistance
• Adopt a more user-friendly battery and charging system
• Reduce cost

Methods

• Sourced and compared linear actuators, batteries, and other components
• Designed 3D printable enclosure
• Added O-ring at cable exit hole to resist water ingress

Results

• Delivered prototype with reduced size, weight, and complexity compared to original product
• Eliminated expensive injection modlign and sonic welding steps from manufacturing