This clamp development program marked Mike's first project at PDI from initial concepts through production. He assumed project leadership during the prototype phase following the departure of PDI's mechanical engineer. Working directly with Kreg's product and engineering teams, the existing patented self-adjusting clamp mechanism was adapted to meet new jaw capacity, throat depth, and functional requirements while Mike led the development of the knuckle-style lever release mechanism.

Mike was responsible for industrial design, mechanical engineering, CAD development, GD&T production drawings, DFM, and tooling kickoff. Throughout the program, and in collaboration with PDI stakeholders, he developed expertise in cam-lock mechanism design, engineering the cam geometry for each clamp configuration while resolving nuanced performance characteristics including hard-start, adjustment range, drop-off, and over-center behavior. This work included the development of a dedicated high-leverage cam lever for the Bar Clamp's "Super Power" locking mechanism.

Mike later spent several months in China establishing a new manufacturing supplier, developing assembly processes, operator training, brazing fixtures, functional test procedures, and production quality documentation through pilot production and product launch.