Pushing Potential Further: Bryan Anderson

From Stargazing to Suspension Guru

Initially drawn to the vastness of space and the allure of astronomy, Bryan Anderson’s path took an unexpected turn away from academia and towards engineering application in the world of mountain bikes. After landing a job at Fox Factory as an engineering technician right after college, his passion for practical problem-solving ignited.

Bryan's nearly 18-year journey mirrors the incredible evolution of mountain biking. He reflected on the industry's shift in trends and bike technology, things like the introduction of 29" and 27.5" wheels, and carbon fiber frames, and components becoming common place along with growing demands for suspension performance and comfort. Bryan recounted the challenges faced in the early days as an engineer, where Fox engineers had to be much more hands on in the entire process of releasing a new product.

“As an engineer, I would be running the shocks in the test lab or going to test sessions with OE customers or athletes myself. You had to follow every aspect of a project from cradle to production,” Bryan stated. “Now, we have a much bigger support team of test lab personnel and newer roles, like the product performance team, to help carry that load.” 

Major Project Highlights 

By scaling up the scope of his projects over the years, Bryan has been involved with over two dozen products. Some of the more notable projects include the Dyad shock for Cannondale, Float DPS, the Canyon Shapeshifter, FOX’s model year 21 40 fork, model year 23 Marzocchi Bomber shock, and FOX’s model year 25 32 Step-Cast fork. 

 “Under the mentorship of some senior engineers at Fox at the time, I was trusted with owning smaller projects,” Bryan recalled. “Eventually, I was given my first full-scale project, the DRCV shock for Trek.”  

The Dawn of a New Era 

Bryan describes how new software tools inject fresh possibilities into the design process. Unlike traditional methods, generative design allows engineers to define parameters like weight limitations, space constraints, and stress factors. The software then iterates to create a 3D structure that can guide the engineer where to add and remove material to create a lighter, stronger part. 

“You have to theoretically validate design work upfront when designing fork chassis parts. With the research, design, testing, and production timelines, you have to get everything as dialed in as possible from the start and go straight to production tooling before a physical part is ever tested in the lab,” Bryan explained. “This technology can help guide us to a more optimized geometry in fewer iterations.”

Bryan's work on the model year 25 32 Step-cast serves as a prime example of generative design power. The new software pushed the boundaries of what was thought possible, resulting in a significantly lighter and stiffer fork crown and lower leg. This innovation not only reduces weight but also paves the way for future advancements in suspension technology.

Bryan expresses his optimism about the continued integration of generative design. He envisions a future where tools help unlock entirely new design possibilities across the product line-up of forks, shocks, seat posts, and other crucial components. It’s a huge technology gap from when Bryan started 18 years ago. Now, as a senior design engineer, with the help of his team and cutting-edge technology, Bryan is again at the forefront of reshaping the two wheeled industry.