Internship Projects

Mechanical Engineering support for integrated microwave assembly manufacturing.

In the summer of 2022, I completed a Mechanical Engineering internship at CAES (Cobham Advanced Electronic Solutions). I designed tooling and updated CAD layouts while managing engineering documentation like ECOs and shop travelers. I performed vibration analysis on IMA housings and validated simulated resonant frequencies through physical testing in the environmental lab. Additionally, I attended weekly cross-functional meetings with representatives from every department to learn how their specific business functions integrated within the company. 

During my summer internship, a manufacturing fixture was used on the line to install RF filters on an IMA housing using oven-cured epoxy sheets. These epoxy sheets require a specific temperature and pressure to cure so the fixture's spring forces were calculated using Hooke's law and validated using a force gauge.

The original design of the fixture also used spring-loaded retaining pins which left markings on the IMA housings, this was prevented by replacing them with a retaining finger machined out of Ultem, a durable thermoplastic. The retaining finger was designed with an interference fit to hold the housing with enough deflection to facilitate installation and removal. The internal stresses and deflection were calculated using cantilever bending moment formulas and then validated after manufacturing.

This heated vacuum stage was used by assemblers to populate PCBs with electronic components. After some errors were found in the 2D drawings, the tooling department requested an Engineering Change Order (ECO) as well as a full 3D model to aid in the future construction of more units.

After working with the technician to make adjustments to the overall design, Solidworks was used to create the machined parts and wiring. To decrease the time spent modeling, several part suppliers were contacted for 3D models of the stage and other purchased hardware.

Finally, all of the drawings were imported into our company's Product Lifecycle Managment (PLM) software and an associated ECO was created and sent for incorporation.