UX Researcher, Concept Designer, Industrial Designer, Manufacturing Engineer
COLLABORATORS
MJ Mayo, Ian Backstrom, Greg Reeseman, Josh Shorey
CONTEXT
A mono-material, high-performance board engineered for durability and circularity.
“The OG” is a hybrid-manufactured longboard that merges additive and subtractive methods to achieve precision, strength, and sustainability. Designed as an all-purpose cruiser, it performs across commuting and performance riding environments.
“The OG” is a hybrid-manufactured longboard that merges additive and subtractive methods to achieve precision, strength, and sustainability. Designed as an all-purpose cruiser, it performs across commuting and performance riding environments.
Key Insights
Sustainability was treated as a design constraint, not an afterthought.
Conventional composite decks lack recyclability and degrade over time. By employing 100% recycled carbon fiber–reinforced ABS, the design reintroduces circularity into a performance product category dominated by waste-intensive processes.
Conventional composite decks lack recyclability and degrade over time. By employing 100% recycled carbon fiber–reinforced ABS, the design reintroduces circularity into a performance product category dominated by waste-intensive processes.
application
Adaptable jigs and DFAM optimization enabled scalable, mold-free production.
I developed a patent-pending hybrid process combining additive and subtractive manufacturing. Custom jigs and fixtures ensured repeatable registration between print and milling stages. DFAM principles guided surface topology, reducing print time and material use while maintaining structural stiffness. Each deck featured a printed, hydrophobic texture that removed the need for grip tape.
Adaptable jigs and DFAM optimization enabled scalable, mold-free production.
I developed a patent-pending hybrid process combining additive and subtractive manufacturing. Custom jigs and fixtures ensured repeatable registration between print and milling stages. DFAM principles guided surface topology, reducing print time and material use while maintaining structural stiffness. Each deck featured a printed, hydrophobic texture that removed the need for grip tape.
impact
A sustainable, data-driven manufacturing system capable of perpetual redesign.
This process supports on-demand, low-volume production using recycled materials, allowing each product to evolve digitally before physical creation. The method eliminates tooling overhead and enables continual iteration at no additional cost.
This process supports on-demand, low-volume production using recycled materials, allowing each product to evolve digitally before physical creation. The method eliminates tooling overhead and enables continual iteration at no additional cost.
learnings + next steps
Automating the subtractive stages is key to scaling hybrid manufacturing.
Manual finishing in the subtractive stages limited throughput. Future development will incorporate robotic automation to scale output and improve repeatability.
Automating the subtractive stages is key to scaling hybrid manufacturing.
Manual finishing in the subtractive stages limited throughput. Future development will incorporate robotic automation to scale output and improve repeatability.