The lime green and black Reap Vulcan time trial bike.
A ducted fan inside a woven carbon fibre cowling.
A white modular motorcycle helmet with a black intercom unit on the side.
A black and clear seagrass planting tool with a T-handle.
A black dome-shaped nail lamp glowing violet inside.

Ethan Greenwood

Industrial designer and design engineer, taking products from early concept to production-ready design.

See the work Get in touch
Vulcan TT Bike Tooling

Selected work

Fifteen projects across product design, carbon composite tooling and production. Swipe or use the arrows to flick through, and select any image to see all its photos full screen.

1 of 15

  1. Forged Carbon Fins

    Forged carbon fibre surfboard fins, from design through to production.

  2. Vulcan TT Bike Tooling

    Redesigned dropouts and fork tooling for Reap's Vulcan time trial bike.

    Read the case study

  3. Seagrass Planter

    A seagrass planting device for the Ocean Conservation Trust, redesigned to be easier to use and to produce.

    Read the case study

  4. Carbon Cowling

    3D-printed tooling for fast-turnaround production of carbon fibre cowlings.

    Read the case study

  5. Vekta Stem and Handlebar System

    A design update for Reap's Vekta, with new dropouts and a new cockpit system. Designed and manufactured.

    Read the case study

  6. Fire Alarm Removal Tool

    A fire alarm removal tool for use on 7-metre poles, for Detector Testers. 300 units delivered.

    Read the case study

  7. Military Aviation

    UAV design and production.

    Read the case study

  8. Recycled Silicone Award

    An award made from waste silicone for CSA, designed and manufactured.

  9. Battery Enclosure Production

    An IP64 sheet metal battery enclosure, designed and manufactured alongside its launch trailer.

    Read the case study

  10. Helmet Intercom Ecosystem

    An intercom ecosystem with brand-specific mounts for popular helmets.

    Read the case study

  11. Carbon Frame Tooling

    Carbon fibre tooling design for MUOV's exercise bike production.

  12. Professional Nail Lamp

    A redesign of an injection-moulded studio nail lamp to reduce cost.

  13. Wooden Globe Spinner Production

    A premium spinning stand for a wooden globe.

  14. Sheet Metal Pizza Oven

    An outdoor pizza oven, designed and manufactured.

  15. Premium Muscle Roller

    A CNC-machined stainless steel muscle roller with quick-release attachments, designed for overseas manufacture.

Case studies

Five projects in depth: the brief, what I did, and how it turned out.

Clients

Companies and organisations I've designed and engineered for.

  • Boost Innovations
  • Detector Testers
  • Fering
  • Kamm Projects
  • MUOV
  • Ocean Conservation Trust
  • Reap
  • Tubs Jackson
  • Volander

About

I'm a UK-based industrial designer and design engineer, working from concept through detailed CAD, prototyping and production-ready design, with deep experience in carbon-composite tooling.

Black and white portrait of Ethan Greenwood.
Education
First-class BA 3D Design, University of Plymouth
Experience
Absolute Product Design, REAP Bikes, Kamm Projects, Boost Innovations
Concept
Research, sketching and early concept development
Engineering
Detailed CAD and design for manufacture
Composites
Carbon fibre parts and tooling for bike frames, forks and components
Prototyping
Prototypes and test models
Production
Taking products through to production-ready design
Software
SolidWorks, Fusion 360, Blender, KeyShot

Working together

I work with founders, studios and in-house teams, on a whole product or on one stage of it.

  1. Concept and form

    Research, sketching and form models that turn a brief into a direction you can test with real people.

    You get: concept boards, form models, renders

  2. Engineering for manufacture

    Detailed CAD, with materials, tolerances and processes agreed with your manufacturer before tooling starts.

    You get: CAD, 2D drawings, a design-for-manufacture review

  3. Prototypes and production

    Prototypes, tooling and supplier reviews, so what arrives from the factory matches what was designed.

    You get: prototypes, tooling support, sample sign-off

Get in touch

Tell me about the product, the role or the problem.