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Why Custom BCDs?
For divers, a BCD (Buoyancy Control Device) is more than just a piece of gear—it’s an extension of themselves underwater. Every diver is unique, with different body types, diving styles, and personal preferences.
Off-the-shelf BCDs might not always provide the perfect fit or function needed for specific diving environments. That’s where Zeagle comes in. By offering custom BCDs, Zeagle ensures that every diver can have a BCD tailored to their exact needs, providing maximum comfort and performance.
How Zeagle Makes Your Custom BCD
Zeagle places a high priority on functionality, performance, and excellence in quality. Customization is at the heart of what we do, representing our commitment to patriotism and service. Over time, we’ve established a strong reputation for crafting robust, made-to-order products that cater to the specific needs of your team or organization.
A critical factor in our ability to uphold these values and meet your expectations is our unique workshop in Salt Lake City, where our custom Buoyancy Control Devices (BCDs) are meticulously tailored to meet your precise demands.
Our decision to maintain Zeagle’s workshop in Salt Lake City also stems from our adherence to the Berry Amendment, which requires Defense Department contractors to utilize U.S.-made textiles and materials for their products.
By observing the requirements of the Berry Amendment, we ensure support for local employment, utilize domestic supply chains, and contribute to the communities where our military personnel reside.
Ever wondered what goes into the making of a customized BCD? We joined forces with Zeagle Product Manager Mani Fifita to delve into the specifics of his team’s creative process.
Q) Hey Mani, tell us a little about the process of building a custom BCD?
Mani) Step #1 is cutting. It all starts with the customer choosing which BC model they want—from extra small, all the way to 5x—in the Ranger, Ranger LTD, Stiletto and Zena models.
As soon as the sales order comes through and I’ve reviewed it, I give it to our cutter, who takes a look. With each order, we have a BOM (bill of materials) that lists all the materials and components that we’ll be using for any given BCD—it breaks down everything we use, from the size, materials, hardware…everything we need to build.
Following the BOM, we grab all the materials we need, then our cutter will cut the shoulder, pockets, vest; and will pick all the components, like the webbing, the cummerbund, etc; and then put all of it into a bin.
Q) What happens next?
Mani) After all of the cuts are made and the materials are collected, we start building.
Specifically, after the cutter has cut some of the preliminary components, the vest and shoulder are built. The components continue to be produced and prepared independently until it comes to me and I’ll install and assemble the whole thing. I’ll put the shoulder together, apply the cummerbund, put the bladders on it, then I do a QC, or quality control.
Q) What does the QC entail?
Mani) We check the seam, check the pockets—make sure to eyeball everything pretty closely. But by the time it gets to this stage, it’s already been checked many times. When it goes through the line, each person has to QC their part, too. So they have to make sure that it matches with the BOM and the order specifications. So, the product gets checked and rechecked multiple times.
After they finish their subtasks, I check it against my list as well, as part of my QC. We all have the same lists, so we’re all checking and rechecking as we go.
That said, everyone is focused on their individual subtask, but I always have the big picture in mind, so sometimes I’ll envision the whole BCD to sort out kinks and minor mistakes, like sizing.
When I see something weird on an order form or something that raises a red flag, I’ll call the customer and sort out the confusion directly. Each BOM sheet contains an average of 75 pieces, so there’s a lot to keep track of!
Q) How do you feel about the work you do?
Mani) It’s the best feeling. When you’re done and you’ve built a piece that someone will trust with their life: it’s super rewarding, But also, those same people will be carrying our name around—carrying our work around.
So, to picture that, someone carrying my work around on their back, is the best thing ever. It’s something that I look forward to. I feel like I’m there, watching them wearing it. But finishing the products, putting them in the bag, watching them ship out—it’s the best feeling.
This name—Zeagle, to me, it’s like my own last name, I carry it like it’s personal. I want it known wherever it goes for how good it is. …The name will last longer than us. I could die next week, but the name will last forever.
That’s what we’re working for: to build that name so it’s known for quality, safety, and love. And I believe that if we build our products with that positive attitude, people are going to feel it. That’s my #1 goal.
Commitment to Quality in Every Custom BCD
At Zeagle, crafting a custom BCD is more than just a technical process; it’s a commitment to delivering exceptional quality and personalized service. Each BCD that leaves our Salt Lake City workshop is a testament to our dedication to excellence, ensuring every diver receives a product that fits their unique needs and preferences.
Our meticulous process, guided by our passion for perfection, ensures that you’re not just purchasing a BCD, but investing in a piece of gear that will enhance your diving experience for years to come. When you choose Zeagle, you choose a tradition of craftsmanship and care that reflects our deep pride in what we do. Dive confidently, knowing that your custom BCD is built with the highest standards of quality and attention to detail.
Click here to design your very own Zeagle BCD!
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