Working for REV Robotics in Carrolton, TX, I prototyped and designed several products that are currently mass produced and available for purchase.

The two black round parts are designed to adapt small DC motors to various educational robotics building systems. The challenge of the design came from integrating several different system together as well as designing the parts to work in any mounting situations.

The part with the V in/out is a small power distribution board. I designed the two part enclosure. This was challenging as I had never designed two parts to fit together. Additionally the engineer who had designed the PCB was no longer at the company making any changes to the board unfeasible. Both were prototyped using SLA printers and revised several times with design reviews before working with the graphic designer and manufacturer. These products taught me the basics of injection molded product design.

Also during my time at REV Robotics I prototyped and designed an extruded TPU product with the purpose to cover aluminum extrusion slots that were unused or as a way to introduce additional friction to a system.

The part above slides into aluminum extrusion as a design and aesthetic element. This was an interesting challenge as I had never designed for TPU or extrusion. An additionally nuance was that this extrusion was to be produced in many color which meant I was responsible not only for the design but also determining Pantone shades. I used FDM 3d printers to prototype the extrusion.

Joining the SAE Baja team my 1st year at CWRU, I joined the ergonomics team and was responsible for the body panel designs.

The goal for this project was to create a process to allow the body panels to be generated through Solidworks based entirely on the wire frame of the car, this allows revisions of the frame elements without significant redesign of the panels. I created a parametric design methodology to generate natural curves and shapes for the body panels of the Case Western Reserve University Baja SAE vehicle. This was a huge improvement from past years as before it was done manually, patterning planes to fit the organic curves of the car. Additionally these models could be pulled from the assembly and used to generate the required molds. Then, partnering with a local design firm, the molds would be manufactured and taken to the biorobots lab to use vacuum pumps to seal and mold the carbon fiber. Unfortunately only a few prototypes were completed due to the covid-19 pandemic and the inability to return to campus. This project taught me the basics of surfacing in Solidworks, the nuances of working with others' models, carbon fiber lay ups, and composite manufacturing.

During my senior year of High School I founded and led FRC team 2714 "BBQ" to a World Championship appearance. We competed across the country and performed very well for a rookie team.

The hardest part of this robot was designing a climbing lifting system. The goal was to have the robot positioned above the top platform pictured in the first image. This was not difficult to do; however in order to score the most points, it was desirable to have as many robots on the platform as possible. With such little space it became impossible to have all three large robots on top at once. The solution was to hang off of the edge of the HDPE platform. This involved 7+ unique prototypes until I designed a custom vacuum pump built with a pneumatic piston, custom gearbox and brushless motor + cam system. It was controlled by custom valves and help pressure with one way valves. The other side of the challenge was vertical movement of 150lb robot. This was done with a custom chain elevator and rope system. Once this system worked it provided our team with a huge competitive advantage even inspiring other teams to create similar systems. I learned the basics of fluid power, pneumatic circuitry, and design packaging and distribution of heavy loads.

As the lead mechanical designer for FRC 2848 I was responsible for picking up "gears" off the ground, or a 13in round disks with holes. The robot performed extremely well, making it to the highest level of play at the World Championships.

The challenge came not from interacting with the gears, but with picking them up quickly and efficiently. The robot should not have to slow down at all to pick up a gear. This was accomplished by having rollers spinning faster than the relative speed of the drive train suck the disk into a pocket. The entire mechanism could then rotate to allow for placement of the gear on a peg. Integrating sensors was a large part of the design as the robot needed to know when it has successfully picked up a gear as well as making sure the intake didn't over rotate. I learned how to implement sensors into my designs, sheet metal design and how to calculate and adjust for relative speeds when designed dynamic systems.

After founding the an FRC team my senior year in high school I set out to build the team a workspace that was versatile enough to take on the road to competitions, but also used regularly in the shop.

I responsible for this project from start to finish. I designed and built the workbench from scratch. The design constraints stemmed from the space we had available at competitions to work in. We only had a 10 ft x 10 ft area to work in. This drove the over all size of the workbench. Outside of that space was needed for toolboxes, 9 heavy batteries, drill batteries, an air compressor and a large workspace. This project taught me the basics of MIG welding, designing with weldments and designing for CNC machining.

From 2017 - 2019 I worked on various parts of the the FIRST Global playing field, these were shipped globally and used by over a 160 teams from different countries.

The design and construction of these were difficult for many reasons. The design of the fields needed to aid in the flow of the gameplay and not rely on any cultural specific knowledge. They needed to be easy to set up and repair, but also durable and consistent. The fields also needed to ship compactly as they were shipped over seas. This meant keeping customs in mind when designing and building, but also meeting a hard shipping deadline. Ultimately the fields taught me how to design modularly, include custom laws in construction and shipping methods, and how to ship internationally.