Identified production bottleneck post bonding and designed and delivered a system which uses two physical bins to manage critical inventory. It's a simple pull system, where the parts are supplied by two rotating containers. As a result ensuring on-time part delivery to the Bonding station…

The final detailed design CAD model screenshot of the 2-Bin Kanban using Part Design, Sheet Metal Design and Assembly Design tools within CATIA. Common stock materials were used such as; 45X45 aluminum extrusions, 20 gauge sheet metal, HDPE sheets, connectors, hardware and signage.

Leadership loves pictures and this picture was delivered to show progress of the 2-Bin Rack. However, I too worked closely with technicians in the part cutting, sheet metal bending and more to not only bring together the 2-Bin design, but to build repor as I always tend to do with teammates.

System completed picture showing all signage including Kanban Process, Kanban Cards and Location Key prior to stocking. In total, system will stock over 50 unique critical parts necessary to meet production.

Pictures shows a CATIA rendering to illustrate the proposed concept of height adjustable rotary tool add-on tool and depth gauges to eliminate rework. The intended material selection for both tools was machined and engraved aluminum. However, due to the typical 1-3 month machine shop backlog I asked myself, why not try 3D Printing the concept?

During this time, economical rapid prototyping or 3D Printing simply wasn’t available. However, as an engineering I loved the idea and had purchased my own personal 3D Printing machine. With this, I decided I would try printing the two concepts and showcase the technology. I was not only endorsed publicly by the regional manager and leadership by the innovative thinking at the time, but was also successful in bringing the technology to the company.

From Shop-Aids to fast turnaround replacement parts, additive manufacturing quickly started to make a positive impact by providing fast turnaround time solutions that normally would have taken months to deliver at a much higher cost.

Customer requested an aggressive +3 magazine extension for a firearm. From concept to prototype using manual measurements, scans and CAD part and assembly design.  

Through several iterations and test fits I was able to finally provide a final design and 3 prototypes using Copper, Iron and Brass Infused PLA resulting in a heavy (relative to normal PLA) cosmetic and functional prototypes.

Current market equivalents are priced at ~35 including spring and fastening hardware. Delivered prototype does not require an additional spring or hardware with material cost at ~$3 and retail price of ~$15.

As an engineer, we love to over complicate things. This is a perfect example with a positive outcome by of turning something as simple as a light switch into a functional piece of art.

I started by searching online for CAD models of the Rocker light switch I had installed in my home followed by manual measurements of the approximate size of the devise and angle of motion. With an initial sketch, I calculated the size and number of gears necessary that would convert a desired 120° of motion to a switch mechanism. My challenge wasn’t so much the design of the gears, rather how to achieve a torque when the handle was pulled to the ON and OFF position. I was able to achieve this by using simple structural beam analysis with varying forces induced by the tightening of the existing screws and cam geometry.

This resulted in my second most popular product with a pending trademark.

Customer requested an aggressive +3 magazine extension for a firearm. From concept to prototype using manual measurements, scans and CAD part and assembly design.  

Through several iterations and test fits I was able to finally provide a final design and 3 prototypes using Copper, Iron and Brass Infused PLA resulting in a heavy (relative to normal PLA) cosmetic and functional prototypes.

Current market equivalents are priced at ~35 including spring and fastening hardware. Delivered prototype does not require an additional spring or hardware with material cost at ~$3 and retail price of ~$15.