Designed graphics & paint treatments for nearly $1 billion worth of products from concept to production in four countries for Aldila, the world’s largest manufacturer of Carbon Fiber Golf Shafts.
Premium global brands included Callaway, Taylor-Made, Nike, Ping, Cobra, Titleist, Ektelon, Dick’s Sporting Goods, and many others.
Created and maintained the industry standard for design and product decoration in a highly competitive global market.
Involved in all phases from project assessment and graphic design to process development, prototyping, project management, planning, production trials, creating quality standards, through manufacturing.
Design & printing of golf club shafts and other sporting goods
- Print directly on small diameter, irregular, tapered cylinders
- Image quality and durability requirements were as stringent as the automotive industry
- Had to print on paints formulated to resist adhesion, causing potential durability issues
- Parts are irregular shapes and sizes, with inconsistency from piece to piece causing difficulty in maintaining print quality
- Production runs as short as 100 pieces with up to 4-5 color prints, requiring easy changeover
- Customers were not charged for high complexity or quality standards. Had to minimize cost in every way possible.
- Processes and equipment were performed by low-skill employees with high rate of turnover.
- Built art and printing departments from ground up in four countries
- Researched and implemented decorating processes for optimal appearance, color consistency
- Researched and implemented ink chemistry, pigments, curing cycles to improve quality, and durability
- Developed ink formulation / color matching systems and quality and color standards to maintain consistency on product manufactured in 4 countries.
- Wrote design, printing, prepress procedures and specifications and trained personnel in printing methods.
- Designed tooling and fixtures for improved throughput and quality including a plastic tool that cost $3 which replaced an inaccurate laser tool. This saved over $100,o00 by reducing rejects for print alignment and allowing faster and more accurate inspection.