Throttling Up Custom Motorcycle Development with SOLIDWORKS Premium


Orange County Choppers

The Company 

Although many people associate Orange County Choppers (OCC) with “American Chopper,” the breakthrough reality television show that debuted on the Discovery Channel in 2002, the company founded by Paul Teutul, Sr., began designing and building custom motorcycles in 1999. Since then, the massive and mustachioed founder has become a celebrity, and the popularity of the television show has brought worldwide fame and a dramatic increase in business to the custom motorcycle manufacturer.

OCC outgrew two previous shops, in Rock Tavern and Montgomery, NY, and now operates a state-of-the-art factory in Newburgh. The onslaught of orders that accompanied “American Chopper” ’s fame created development and production challenges that the custom shop could no longer address using its original approach. Senior Designer Jason Pohl, now a regular on the television show, was working on the prototype for a video pinball game in 2004, when Teutul contacted him about joining OCC. "I created some virtual chopper models for the game that were loosely based on OCC designs,” Pohl recalls. “Paul, Sr., saw my work and realized how computer modeling could help the company evolve from a design and production standpoint. He recruited me to join OCC in a concept artist and 3D modeling capacity."

The Challenge

Accelerate the sophistication and efficiency of motorcycle design to boost production, enhance quality, and control costs.

The Solution

Implement SOLIDWORKS Premium design software to take advantage of design visualization and automated production technologies.

The Result

  • Accelerated time-to-market by 100 percent
  • Shortened design cycles by 75 percent
  • Cut development costs by 50 percent
  • Eliminated several rounds of prototyping

“With SOLIDWORKS, we can refine the design, and then control the production of parts with a high degree of precision. SOLIDWORKS has become the backbone of our development effort because everything  evolves around the SOLIDWORKS model.”

Jason Pohl
Senior Designer