RVLock China Costdown Sprint
about.
The Atlas is a universal RV door handle featuring a patent-pending locking and adapter mechanism that achieves multiple locking configurations from a single SKU — reducing cost and complexity while increasing locking strength from 66 lbf to 500 lbf. Developed through to production. Although this was a team effort, all work presented here is my own.
SCOPE
12 Months
YEAR:
2023
ROLE
Industrial Design, Design Engineering, Testing & Validation
challenge.
THE PROBLEM
The existing locking pin geometry was failing at 66 lbf — well below what a robust RV door handle demands. The challenge was to redesign the pin system to dramatically increase locking strength without adding cost or assembly complexity. FEA was used to iteratively optimize pin geometry, identifying stress concentrations in the original design and driving decisions around wall thickness and contact surface area. Material selection played a key role — evaluating candidates against strength, manufacturability, and cost targets for high-volume injection molding and die casting.
LINKAGE BAR LOCKING SYSTEM
US20250109617A1
The locking system was redesigned around a linkage bar mechanism that locks the deadbolt and paddle simultaneously — improving security and simplifying internal assembly.
Linkage bar locks deadbolt and paddle in a single motion
LOCKING PIN GEOMETRY
FEA
Early iterations used flat-face-to-flat-face contact geometry. FEA revealed stress concentrations at the interface driving failure at 66 lbf. Pins were redesigned with an 11-degree angled contact face, distributing load into the exterior casting.
Early concept (left) showing stress concentrations exceeding yield strength. Optimized geometry (right) dispersing stress across the assembly.
MULTI -FIT ADAPTER
US20250109619A1
A sheet metal subassembly with a swappable deadbolt in two lengths. Option A for cutouts offset from the door edge. Option B for cutouts at the edge. All configurations modeled as Onshape assemblies for rapid switching.
Linkage bar locks deadbolt and paddle in a single motion
INDUSTRIAL DESIGN
A new bevel was developed to modernize the handle silhouette, improve grip ergonomics, and unify the aesthetic across RVLock's product line.
Linkage bar locks deadbolt and paddle in a single motion
results.
To validate locking strength, I designed and built a custom tensile test frame fitted with a load cell, capable of applying and measuring pull force on the locking mechanism directly. This gave us in-house validation without relying on external testing labs. The redesigned pin geometry achieved 500 lbf — a 7.5x improvement over the original 66 lbf — confirmed across multiple samples on the test frame.
testimonial.
The new lock was easy to install, the instructions were easy to review both written and the videos. It fits beautifully and looks like it belongs there from the factory. No more need to carry a key when leaving the rig. No more I forgot to bring the key with me. Love the new lock!
11
Michael S.
Verified Customer
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