June 2021 to August 2022

I interned as a Tooling and Packaging engineer. Where I designed tools, jigs, and fixtures for factories and production aid. I used, practiced, and learned technical skills in mechanical engineering principals, CAD software, additive manufacturing, milling and machining, FEA, hands on development, team work in large groups, and product ownership.

Designing production aid tools and jigs

I designed and solved 5 mechanical engineering projects during my 2 month internship. I led product design as owner and was responsible for design and delivering a viable solution.

3D printing Designs

Designed tools with additive manufacturing principles and using FDM printers.

FEA studies

I learned to conduct stress analysis with senior engineers using ANSYS workbench 20. I conduct analysis studies on beams and fixtures and a verification of mesh quality and results.

January 2020 to June 2020

I worked full time as a mechanical engineer intern for the pneumatics division. Where I experienced, learned, and grew in a variety of areas. I digitally routed the pneumatics lines on full truck assemblies, specified and tested COTS fittings, designed new product variant, conducted diagnostic testing, self taught programing in Python creating a GUI, and created instruction drawings for Covid-19 ventilators by MIT with Volvo Group parts.

CAD routing of Pneumatic lines

I worked on large assemblies, routing pneumatic lines using PTC Creo 5.0.

I worked on adding a complete pneumatic line [red] for the testing and development of auto leveling mechanism and sensing, from the electronic button inside the cabin interior to the end pneumatics connectors. Also I routed the electrical wiring that supports this new system [blue].

New pneumatic connectors: by Knogsberg

I supported a senior engineer in the documentation and instruction specifying new pneumatic connectors by Knogsberg.

Also I tested and determine the torque necessary for the new fittings to operate  and also prevent air leaks.

New POGO stick backet

I work on designing a new pogo stick bracket variant. The new design used a clamping fasteners rather than the previous bolts and nuts.

The previous bolt nuts was constrained by the chassis bolt pattern limiting the placement of the pneumatic bracket and sometime leading to interference issue in the factory.

As result I create a bracket design that was independent of the chassis' hard bolt patterns, giving the pneumatic bracket more range and flexible of placement.

I create the engineering drawing and fabricated the part and test the part on a truck for fitment.

Pneumatics Hands on testing

I worked hands on to conduct diagnostic pneumatic leak test. Researching and collecting data points to conclude a analyses result. 

Attaching a prototype diagnostic tool, I test over 80 trucks' pneumatics system for air leaks. Through the OBD2 port I run developing software and held open discussion and feedback of its usability.

I collected all the data into an comparison chart, and presented to division leadership. I then collected 50 data points remotely data from the trucks gps data collection and highlighted possible points of interest.

GUI Development Python, Matlab, Excel

I was self taught and learned python on the fly. I coded a custom GUI using python. This GUI is independent to a similar MATLAB code but frees the company from expensive licensing ties of MATLAB. The application creates simulation of configuration to show the user buildable and non-buildable variants.

The GUI selects four independent variables from multiple sheets from an excel data set. The GUI tells the user live feedback of plausible and non-plausible configurations for the pogo stick by embed calculations of truck cabin length, rear axle position, hose length, and fifth wheel placement. The GUI also includes a graphic illustration that updates automatically. It also does quick calculation giving the user clear measurements in mm and feedback with colors green, red, and yellow.

Installation document drawing corrections

I worked on PDF documents that guides the assemblers during installation of truck configurations. I supported the screenshot and numbered the balloons and release the document using an in-house PDF formatting.

Covid-19 response

2017 to 2018

I worked in a team of 4 for a senior design project with GE Aviation Manufacturing. In support of the new LEAP engine, the challenged was indication process of a forward outer seal of the turbine jet engine. The fixture spun on a 600 lb cylindrical fixture and need to be indicated for flatness and roundness of 0.0005". The process would take upwards of an hour and led to downtime of the CNC and increase operational cost.  By designing a workbench fixture for the machinist, they could queue and indicate the component outside of the CNC machine saving the company hundreds of hours over a year.

Design

I created the design using PTC Creo, researching ergonomic positioning, and understanding the objective requirements.

I designed a workbench fixture as the manufacture engineer request. Allowing for the operator to conduct centering alignment, preparing the cylindrical tooling for CNC milling. This reduce the milling machines downtime by hour for several thousand part per year which yields high ROI.

Fabrication

Proof of concept

Design iteration

Using a SKF NRT320 B super precision axial radial cylindrical roller bearing, the fixture will be fastened to the adapter plate that is fastened to the bearing.

Revisiting the project

I deliever the result with the team members to the manufacture engineer as proof of concept with recommend changes to meet the requirements. The fixture was so large and heavy at nearly 600 lb it was difficult to  absolute center and rotate without proper lifting equipment, which led the challenge of rotating such a large fixture for precision.

For the next steps: after completing the project and revisiting the idea, I designed a rotary table that is shown below

I joined WCU's Baja first club team in 2014. I got hands on fabrication experience building the chassis as a member my first year. Later on took the lead role of Powertrain, where I designed the powertrain packaging layout using PTC Creo. I led new team members in the fabrication with a CNC laser cutting, machine shop equipment, and specified COTS hardware to use.

I self taught myself to conduct stress analysis using ANSYS workbench where I recreated the failure point of the suspension components that was damaged in the competition races.

Some of the cad models are upload to my cad portfolio on grabcad: https://grabcad.com/library/sae-baja-powertrain-assembly-1

Initial design, Imported Engine, differential, and CVT CAD files.

Engine is Brigg Stratton 10 HP

Differential is DINAN H12

CVT is CVTech

Two deigns where considered, small wheel base vs lower CG.

Back view to check alignment, lower CG was chosen, and center differential drove placement of the rest of the powertrain.

Final result was fabricated.

challenged face was no FEA was conducted, design changes were required to overcome interface from version 1, and power output was below desired.

Revisiting the project:

If I were to redesign the mounting bracket: I would create this below. The service windows allows access to mounting the the engine.

Electric Vehicle

I support the FSAE Electric Vehicle team at NCSU to build and test NCSU's first Electric FV. I also design and build electronic packaging components and machine chassis and suspension components.

Cascadiamotion Motor controller

Rinehart PM 150 DZ

EMRAX 228 Motor

Steering wheel display assembly

I designed and build the display assembly for the steering wheel using PTC Creo and rapid prototype a design.

I imported the steering wheel and design used assembly level references. This allows for overall complete design and design check of interface and fitment.

I 3d printed a prototype using my own Tevo Tornado printer with Cura software and 0.2mm nozzle with slower print speeds to produce high quality prints.

Once the geometry was confirm, waterjet carbon fiber sheet using protomax

Connector face plate

DTM--04 cover

Accumulator Carrying handles

S: Formula SAE 2021-2022

T: Make handles that will carry the accumulator by yesterday, for servicing. The Accumulator weight ~130 lb

A: Using thick material and mounting holes as reference, handles were fabricated by the end of the night.

R: Carrying handles work well. No analysis was done but solution works well.

Milling and machining

I operated a manual milling machining and machine shop equipment in milling suspension clevis and jigs for chassis components.

part being fabricated is a suspension pick up point.

Composite Carbon Fiber

I helped lay the carbon fiber aero components using the vacuum bag method. Laying the carbon fiber on tooling board and with perforated and absorb-mat.

Once cured the part where then cut to final dimension then fitted with internal structural aluminum "fishes" then boned.

Procurment of Sponorship

HBFuller

I secured a new product sponsor for FSAE EV.

S; 2022 NCSU FSAE EV

T; We need to encapsulate the battery cell with a NHV material.

A; I research EV battery encapsulation solutions and came across HB fuller on a Youtube at a trade show. Their product was the perfect solution. 1/5 the way of epoxy and specialized in thermal propagation protection. I reached out to their contact us page.

R; I brought onboard a new sponsor that excels in EV products. We utilized there EV 4006 foam product.

Blicke

Setting: FSAE EV 2021-2022

Task:  FSAE EV needs a accumulator cart for events that always had brakes on.

Action: I research online for casters and wheels design with Deadman switch features. I found Caster Connection which lead me to Blicke Casters. I reached out for a sponsorship and received $750 product sponsorship.

Result: The accumulator cart is currently being build. the switch will be activated by a dual brake lever.

Cable lead holder

The team was looking for a custom cable lead holder. I designed using PTC Creo sheetmetal and cable holder dimensions. I had the part waterjets and braked into shape.

Engineering Drawings

3D printing

For the Electric vehicle a energy capturing device is required to install on each vehicle, but parts aren't given to team until competition day. Using past data and model. A sample piece is 3D printed in preparation for placement, to avoid part interface.

Using a Strasys FM150 and GrabCAD software the sample part was printed in 3 hours.