collaborative robot

Sawyer is a collaborative robot designed to execute tasks that have been impractical to automate with traditional industrial robots.  Sawyer is a 7 DoF robot arm with a 1260 mm reach that maneuvers into tight spaces and operates in work cells designed for humans. Built-in force sensing capabilities allow it to make adaptive decisions as tasks run, enabling Sawyer to work precisely (+/- .1 mm), while operating safely next to people.
My Contribution:
  • Conducted FEA studies using SolidWorks Simulation to determine proper materials, calculate safety factors,  and to optimize geometry for stiffness and weight
  • Designed aluminium diecast shells using advanced surfacing techniques in SolidWorks 
  • Design injection molded components requiring EMI/RFI shielding
  • Developed accelerated reliability tests for the robot actuators
  • Designed a tool free end effector attachment mechanism  to allow for quick EOAT changeovers. The ClickSmart Plate is patent pending.
  • Performed thermal analysis and devoloped thermal manangement strategies for the actuators

industrial headset

A wireless communication headset that allows the user to communicate directly to another headset or interface with a mobile radio while remaining protected from unsafe noise levels
My Contribution:
  • Responsible for 100% of the mechanical design from design input to validation
  • Used surfacing techniques in SolidWorks '14 to achieve organic shapes and curves
  • Chose materials for tough users, extreme temperature, and corrosive environments
  • Used SolidWorks Simulation FEA to analyze component designs and materials 
  • Created 25+ new parts, including injection molded, stamped, extruded, sintered, and compression molded
  • Designed headband to minimize number of components while allowing  end user to freely switch between over-head and behind-head configuration (patent pending)
  • Successfully designed and tested to MIL-STD 810 and IP-67 (waterproof)
  • Used Stratasys FDM 3D printer for early stage prototyping
  • Worked closely with our electrical engineer in order to fit a large number electronics in to a tight package including 6 microphones, an 18650 battery, 2 large speakers, a DECT module, 7 tactile switches, an LED,  and a USB input
  • Created all mechanical drawings and assemblies
  • Sourced components and inspected first articles to ensure quality
  • Wrote build instructions for domestic and overseas manufacturing
  • Created test fixtures to simulate life-cycle testing using arduinos to control step motors, actuators, and servos.

digital intercom

An intercom that can connect up to 4 radios and 4 additional auxiliary devices allowing users to clearly communicate using any combination of wired headset, wireless headset, phone, or radio
My Contribution:
  • Responsible for 100% of the mechanical design 
  • Designed and tested intercom for high vibration environments (vehicle mounted)
  • Designed a membrane switch panel  to interface with our PCB with 12 tactile metal domes and 44 LEDS
  • Created all mechanical drawings and assemblies
  • Wrote build instructions for domestic and overseas manufacturing

waterproof head unit 

A weatherproof remote head unit for a digital intercom allowing users to control their intercom from outside of their vehicle
My Contribution:
  • Responsible for 100% of the mechanical design 
  • Created an IP-67 (waterproof) design using off-the-shelf o-rings and fasteners and new 2 injection molded  parts
  • Designed a membrane switch panel  to interface with our PCB 
  • Created all mechanical drawings and assemblies
  • Wrote build instructions 

photovoltaic roofing tile

A contoured photovoltaic roofing tile designed to seamlessly install with traditional terracotta roof tiles
My Contribution:
  • Responsible for obtaining UL and ICC certification
  • Built an internal test lab with industrial oven, thermal chamber, humidity chamber, and tensile testing machine
  • Tested to ensure 25 year product life using both internal and external labs
  • Worked with a small team to build out new manufacturing facility and to qualify new equipment and novel manufacturing processes
  • Used SolidWorks for drawing creation and photorealistic rendering

burn in and test sockets

Engineer-to-Order Test & Burn-In sockets for small scale electronic packages included CSP, µBGA, Bump-Array, QFN, QFP, MLF, DFN, SSOP, TSSOP, TSOP, SOP, SOIC, LGA, LCC, PLCC, TO, and any SMT package.
My Contribution:
  • Responsible for creating engineer-to-order sockets from customer requirements
  • Created a VBA program to automate the mechanical design of ETO custom sockets reducing the engineering time per order from multiple hours to less than 30 minutes
  • Qualified a new high speed driller-router to increase production efficiency.