What’s your “route” been at D-Riven?

“I started at D-Riven as a Contract Engineer, where I quickly took on responsibility for upcycling major portions of the Milk-Carton Flame Sealer: the infeed, register, and folding systems. By developing a detailed CAD model of the machine and producing designs that could be carried through to implementation, I earned the opportunity to transition into a direct role on D-Riven’s Upcycling team. Since then, I’ve continued building on that experience by tackling new challenges in machine upcycling and mechanical design.”

How does it feel knowing you’re helping create a safer environment through your work?

“Knowing that my designs have a direct impact on operator safety creates a heightened sense of responsibility in my work. It makes me more deliberate, looking beyond whether something simply functions to how safely it can be operated, serviced, and maintained. There’s real satisfaction in knowing my engineering decisions can make a tangible difference for the people who operate and maintain this equipment.”

What’s the toughest “roadblock” you’ve helped the team navigate?

“Upcycling the Packout Station layout for the Smartpour Sealer. Balancing budget, timing, and ergonomics at the same time gave me a new appreciation for the challenges our Project Managers navigate on every project. Through research, cost comparisons of high-quality conveyance systems, physical ergonomic trials, and new DFM skills related to CNC milling, we were able to address ergonomic requirements while introducing opportunities for significant cost savings.”

How have you helped keep the Upcycling process moving smoothly this year?

“By independently researching contemporary solutions to better understand the technology behind our belt-driven Sealer machines. I’ve applied those findings through improved roller-bearing fits, longer belt life via snub roller placement, and more efficient material selections that simplify downstream fabrication. I enjoy taking what I learn through research and standardizing it into practical equipment improvements for the team.”

What’s one piece of advice for someone just starting out in upcycling?

“Resist the urge to immediately redesign what you see. First understand the original purpose of the assembly and its subassemblies, then reverse-engineer the design intent behind the original engineer’s decisions. Once you understand the ‘why,’ you can identify opportunities to improve function, reliability, or maintainability. And remember: optimization doesn’t always reduce cost. A modest increase in price can be worthwhile if it delivers a meaningful improvement in robustness or functionality.”

Once you understand the ‘why,’ you can identify opportunities to improve.

Colton Hunley, D-Riven Upcycling

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Thank you, Colton, for your hard work and dedication! 🛣️

Special thanks to Katrina Rivenburgh for conducting this interview | Graphic design & digital content by Rachel Rivenburgh