Crye Precision
project overview.
Throughout my time at Crye Precision, my primary focus was designing specialized fixtures for automated sewing machines to enhance the efficiency and quality of sewing processes in the production of tactical gear and garments. The goal was to streamline manufacturing, reduce manual intervention, and ensure consistent, high-quality stitching in the creation of advanced tactical apparel.
my roles.
Product Designer
Product Manager
collaborators.
Sean Flaherty
Joe Avedisian
tools.
SOLIDWORKS, DraftSight
background.
Crye Precision is a company that designs and manufactures tactical gear and garments, such as uniforms, armor carriers, pouches and helmets.
The production of these products involves numerous intricate sewing steps.
My role was to improve both the efficiency and quality of these processes.
Working closely with the Director of Manufacturing, I analyzed the workflow and identified the best approach to address the challenges. We decided to replace certain manual sewing operations with automated processes, utilizing specialized machines (such as the one shown below) to streamline production.
the problem.
We identified four areas or "pain points" we needed to address for the various manufacturing processes at the factory.
Accuracy: This refers to how close the product is to meeting accepted values. For example, each stitched part on a garment had an acceptable tolerance for how far it should be from the edge, the deviation from straightness, and the tension of the stitch itself.
Precision: This refers to the consistency of the products produced, or the reproducibility of results.
Speed: This refers to how much time it takes to complete one step in the entire manufacturing process.
Safety: This refers to the risks involved, including but not limited to injuries to workers and damages to products.
design process.
Research Existing and Historical Methods
This initial phase focuses on thoroughly investigating both current and past approaches used in the manufacturing process we're aiming to improve. The goal is to fully understand the problem space, identify what has already been attempted, and avoid duplicating previous efforts.
Brainstorm and Ideate Solutions
I begin sketching out initial concepts and design ideas. This is a hands-on, iterative process where I explore a range of possibilities—from rough concepts to more refined solutions. Collaboration is key: I often bounce ideas off fellow engineers, and I regularly consult with our technical designer, whose deep knowledge of the garment industry helps surface practical constraints and considerations that might impact the viability of each concept.
Refine the Selected Design
To move from concept to implementation, I schedule a design review with my manager (the Director of Manufacturing Engineering) and our team’s machinist. During the meeting, I present 2–4 design concepts and actively solicit feedback to evaluate each option’s feasibility and impact. Together, we select the most promising solution. From there, I take the lead on refining the chosen design in SolidWorks, translating the concept into a detailed and manufacturable model.
Prototype
After finalizing the design in SolidWorks, I hand off the completed file to our machinist, who fabricates the prototype using a CNC machine. This is where the design transitions from digital model to physical form—bringing the concept to life and allowing us to evaluate it in a real-world context.
Testing
While the prototype may look promising, it rarely performs flawlessly on the first try. During testing, I carefully evaluate how the design functions under real conditions, noting any performance issues or unexpected behavior. This phase is critical for identifying adjustments needed to meet our performance goals and ensure the design is both functional and reliable.
Redesign
Most prototypes don’t require a complete overhaul—minor tweaks are often enough. Based on insights from testing, I revise the SolidWorks file accordingly and coordinate with the machinist to update the prototype in the shop.
In more complex cases, when the design falls short of core requirements, I may pivot to a substantially different approach. Phases 5 (Testing) and 6 (Redesign) often repeat in cycles until we arrive at a solution that meets all functional and quality standards.
Handoff and Analysis
Once testing confirms that the solution consistently meets our performance standards, it's ready for handoff to the end user. I’m responsible for delivering the final product, providing clear instructions and demonstrations on its use, and gathering feedback for further evaluation. This often includes capturing video footage of the product in use, which helps identify any remaining issues and informs future iterations or process improvements.
results and takeaways.
These tools saved more than 10,000 man-hours over the course of a year—equating to at least $300,000 in labor savings.
Over 10 innovative tools were designed, each enhancing accuracy, precision, and safety while significantly reducing the time required to complete key tasks. The improvements in accuracy and precision led to fewer rejections during quality inspections and a noticeable reduction in customer returns, further driving down costs.
During my time at Crye, I was able to go from shadowing my manager and other engineers, to leading my own projects. Other than designing the sewing fixtures, I also gained experience planning project timelines, coordinating with other departments, relaying technical information (sometimes in a different language), and analyzing product results and feedback to better tackle future design tasks.