Émonda
I initiated the ten-pound bicycle concept and led a team in Émonda’s development. Trek’s launch-announced weight for the original SLR 10 was 10.25 lb for a complete 56 cm bicycle.
The ten-pound bikeWork with ReggieComposites × ManufacturingAvailable for engineering consulting, contract, and leadership work
Reggie Lund
Composites & manufacturing engineer · Former Trek engineer · Madison, WI
I develop composite products and the manufacturing capability behind them.
I’m a former Trek engineer with more than 20 years of experience across manufacturing engineering, composite product development, and production programs in Taiwan and China. My work includes initiating the ten-pound Émonda concept and leading a development team, co-inventing the pivot behind IsoSpeed, and training design and process engineers at Giant and Quest.
I connect material selection, laminate design, test results, and manufacturing requirements. That work includes technical decisions through production release, along with the development and troubleshooting needed to make a design repeatable.
20+years at Trek10.25 lbÉmonda SLR 10 at launch2overseas manufacturers trained7engineering case studies
Engineering · at Trek
Selected work
Three projects: the product, the production capability and the test system.
01
Quest Composite
Beginning with the Domane program, I worked on frame development and trained Quest’s design and manufacturing/process engineers in composite design, production and troubleshooting.
Developing Domane production
Bicycle Treadmill
I pitched the testing capability, gained leadership approval and worked with Woodway on the specifications. Trek’s development account follows the work from road molds to the custom machine.
From road molds to a test machineThe situation
A part that works once is a prototype. Working every time is the job.
You have a composite product that has to hit a weight, a price and a production schedule at the same time, and right now it only manages two of them.
Maybe the design is close but the manufacturer can’t make it the same way twice. Maybe a new factory needs to learn your product before launch. Maybe a part keeps failing, and the test data, the supplier and the design team each have their own theory.
None of that belongs to design or manufacturing alone. It sits between them, and that’s where I’ve spent my career.
What I do
I take the part from laminate to production release.
On my programs, material selection, ply orientations and final weights were my responsibility. I held final approval for test standards and results, quality-control checks and the technical go/no-go decision for production.
I set development priorities with the manufacturer, judging which direction had the strongest chance of working against the product requirements, the final weight and the price target. Where equipment affected a project, I reviewed its technical feasibility and made recommendations.
And I teach it. At Giant and Quest I trained the design engineers developing the laminates and the process engineers producing and troubleshooting them, in writing between visits and beside them in the lab and on the factory floor.
Email ReggieExpertise
The expertise behind the projects
Composite design
Material selection, ply orientation and laminate development were a substantial part of my own hands-on work. I also interpreted tests and investigated failures, connecting the design decisions with the results from the part.
“The modulus is the technical term for stiffness – how much it will stretch when you apply a load.”
Materials and manufacturing processes
I selected materials and developed manufacturing techniques and processes. The work had to account for product requirements, final weights and price targets, alongside the practical requirements of making the design.
See it inGiant Manufacturing
Testing and failure analysis
I worked on test-results interpretation and failure investigation and analysis. I also worked with cross-functional teams on warranty trends and product improvements and on improving ride-test procedures.
Manufacturer development
I taught design engineers to develop laminates and manufacturing/process engineers to produce and troubleshoot them. At Giant and Quest, this included sustained written guidance, development-lab work and time on the factory floor beyond the first launch.
Systems integration
I led the Domane+ SL project and directed the suppliers integrating the motor, battery, display and controls. The drive system was TQ’s; getting all of it into something that still rides like a road bike was the job.
See it inDomane+ SL
Where this comes from
Manufacturing came before product design.
Before Trek, I worked as a process engineer at ATK Composites in Salt Lake City. I worked to Boeing’s product specifications and critical design parameters, coordinated manufacturing improvements with its quality engineers and worked with scheduling on deliveries.
At Trek in Waterloo, I worked on carbon-material utilization, machinery troubleshooting, throughput and process documentation with supervisors and production workers. Product development and design followed.
I implemented DesignConcept software and developed a process for flattening 3D shapes into manufacturing preforms, and assisted with step-joint development and its manufacturing process. Later I led Road & Speed R&D meetings, coordinating current development work, future needs and timelines with the core team.
Record
Inventions and published engineering
I am a named co-inventor on the following selected records:
| Invention | Record and collaborators |
|---|---|
| Passive seat-tube pivot | US 8,857,841 B2 Reggie Lund and Christopher Pomering |
| High-compliance seat tube and internal cable routing | US 11,661,134 B2 Reggie Lund and Steven Moechnig |
| In-tube cavity and storage | US 11,511,824 B2 Steven Moechnig, Reggie Lund and Matthew Yerke |
I am also a co-author of Trek’s 2016 Madone white paper, which documents the team’s engineering and validation work.
Press
In the press
Selected coverage of my work at Trek. Titles are as each publication gave them at the time.
- New 2023 Trek Domane ditches adjustable IsoSpeed Decoupler
Quoted as the Domane’s lead design engineer, on the frame’s IsoSpeed changes, laminates and tyre clearance.
“The capacity for larger tyres improves comfort to such a degree that it dwarfs what the front IsoSpeed device could offer.”
- Understanding carbon bike frames: what does unidirectional, woven and high-modulus fibre all mean?
Interviewed as an R&D engineer at Trek on fibre stiffness and strength, cloth and unidirectional plies, and laminates that pass testing.
- Trek Performance Research: The story behind the ride
Names me among the engineers behind Trek’s field testing and the cobblestone molds that led to the test treadmill.
- Syensqo introduces more sustainable polymers on the new Trek Madone road bike
Quoted as Senior Mechanical Engineer at Trek on lower-carbon polymer parts for the Madone Gen 8.
“These parts are just one of the many things Trek is doing to reduce the impact of our products.”
How I workCheck the math. Then let the part decide.
01
Start from the requirements
Weight, price, the product’s requirements and what the factory can actually make. Priorities get set against all of them, with the manufacturer in the conversation.
02
Design the laminate and the process together
Material, ply orientation and manufacturing method are one decision. A layup that can’t be built the same way every shift isn’t finished.
03
Let the test evidence decide
Interpret the results, investigate the failures, approve the standards. When the model and the part disagree, find out why before anyone builds more.
04
Teach it, then release it
Written guidance between visits, time in the lab and on the floor, and a go/no-go call when the process is ready for production.
And it loops:
- Requirements
- laminate
- process
- test
- failure analysis
- training
- production release
- field data
Warranty trends and ride-test results are test data nobody scheduled. I worked on both with cross-functional teams, and what showed up in the field went into the next program.
Ships · Digital
The software.
Sometimes the project is software.
02★ Featured
HammerDo.com
Talk to a verified trade pro before you touch the wall. Flat price, no service call.
An idea Emily and I developed together. She built the product, connecting people working on home projects with trade expertise.
Early access
hammerdo.com
0110:02In Progress
A product in development that lets bands publish a setlist and fans pay to move requests up during a show, while the band keeps control of what gets played.I built this one myself. Bands publish the songs they are willing to play, fans pay to move requests up during the show, and the band keeps control of the set.
digital.nulund.com
Makes · By hand
Furniture, builds, and shared projects
Shared builds at home, credited by who did what.
03★ Featured
Rooftop Garden
Two growing seasons into a rooftop garden designed and built for everyday use. Phase one is complete, with more work planned.
I did most of the build; Emily painted the panels.
Phase one complete · in use
01Desk and Shelving SetIn progress · two of three bays complete
02Pantry CabinetIn Progress
A proper pantry, finally.Built with Emily.
03Montessori ShelfDone
CNC-cut. Kid-scaled. Actually useful.I designed it in CAD and cut it on the CNC. Emily sanded and assembled it.
Whether this is a fit
I’d rather find out what breaks first on paper than on your production line.
Bring me in when
A composite product needs to meet weight, cost, performance, and manufacturing requirements; a production process needs development; or test results and field failures need an experienced technical review.
Scope of the work
I work with design teams and manufacturers on materials, laminates, testing, process development, and production decisions. My systems-integration work connects supplied components into a product; it does not imply that I design their motors, firmware, or electronics.
Working arrangement
Project, contract, and leadership engagements. Remote for design reviews and test data, with on-site work when the problem requires time in the lab or on the production floor.
Work with us
Bring the drawing. Bring the part. Bring the problem.
A composite product in development, a manufacturing problem, a material decision or a part that keeps failing. Send what you have, what it needs to do and where the work is getting stuck.
A project, a contract or something longer. Based in Madison, Wisconsin.
Broader product or engineering needs? Explore Nulund’s capabilities