The Problem

A paper creasing machine required a worker to manually load and unload cardboard sheets on every cycle — standing directly in front of a heavy rotating mechanism with no sensors or safety interlocks. The process was slow, limited uptime, and put the operator at risk on every cycle.

The Solution

Designed a full Special Purpose Machine (SPM) from concept to prototype in SolidWorks to automate the load and unload sequence. The machine used pneumatic grippers to pick and place paper sheets, motors to replicate the human loading motion, and a sheet metal storage and enclosure system to feed stock continuously without manual intervention.

Key Design Decisions

• Pneumatic gripper selected for paper handling — compliant enough to handle variable cardboard thickness without damage

• Motor-driven articulated arm designed to mimic the angular loading motion of the existing machine's moving platen

• L-beam structural frame designed and fabricated end-to-end with sheet metal enclosure

• Paper storage integrated into the structure to enable continuous feed without operator intervention

What Was Built

Structural frame and sheet metal enclosure were fabricated as a working prototype before the project was discontinued. The full machine CAD was completed in SolidWorks across multiple concept iterations.

Key Skills: SolidWorks, SPM Design, Pneumatics, Sheet Metal Design, DFM, Concept Development, Structural Fabrication