Spring-loaded Ball Launcher

Collaborators: Team of 6

Designed and built a mechanical system capable of consistently launching ping pong balls into a target bucket at adjustable distances (10–20 ft), focusing on system reliability, safety, and production optimization. 

• Design a spring- loaded launcher capable of accurately targeting distances between 10 and 20 ft

• Identify key mechanical and operational variables affecting launch performance

• Optimize launcher settings using statistical methods (DOE) for precision and repeatability

• Improve system robustness against noise factors such as ball wear and user variability

• Ensure manufacturability and performance reliability through functional modelling and tolerance analysis

• Prototyped the launcher with adjustable pitch and modular barrels using SolidWorks and 3D printing.

• Created a Product Functional Diagram (PFD) to map subsystem behaviour and input-output relationships.

• Conducted Failure Modes and Effects Analysis (FMEA) to mitigate mechanical risks.

• Ran a full-factorial Design of Experiments (DOE) in Minitab to assess main/interaction effects.

• Performed a Taguchi DOE (L4) with noise factors (new vs worn ping pong balls).

• Conducted tolerance analysis using Worst-on-Worst (WOW) and Root Sum Square (RSS) methods.

Microsoft Office (FMEA, Tolerance Analysis, Root Sum Square Analysis), SolidWorks, Minitab, 3D Printing 

Response Table and Main Effects Plot for Robust Design Analysis from Minitab

• Successfully demonstrated mechanical feasibility with printed prototypes. 

• The conveyor operated reliably with simulated waste input.

• Macerator achieved the target paper breakdown 

Through this project, I learned how to combine physical prototyping with data-driven methods like DOE and tolerance analysis to make precise, reliable design decisions.