Embedded Files
Medical Device Assembly Machine
Medical Device Assembly Machine
2022-2024
I collaborated with two other mechanical engineers to design the most complex project I've had the privilege to work on. The machine is constructed with over 3000 parts, compliant with FDA & OSHA regulations, and operates in an ISO Class 8 clean room environment.
Pieces of the product are fed into the machine, automatically oriented, and assembled at a rate of one part every two seconds (30ppm). AI vision systems identify defects and remove any bad parts into a reject bin. Good parts are fused together by ultrasonic welders and the finished product is unloaded into a bin conveyor
2021-now
As a machine designer, I've compiled links to the best reference material & commercial parts I use on my Automation Resources page.
I use the page on a daily basis to quickly navigate the clutter of vendor websites and inspire my design choices.
I encourage my colleagues to use the site and provide feedback!
Casting Robot Cell Concept
Casting Robot Cell Concept
2024
Two robots would work side by side to cast parts for an advanced machining process.
Custom Packaging Machine Concept
Custom Packaging Machine Concept
2023
This concept machine would place packaging into fixtures on a conveyor before they are laser marked. After a worker loads the fixture with a product, it stops through a few stations to complete the packaging process. A worker unloads the packaged product and the fixture starts the cycle over again.
Bundler Upgrades
Bundler Upgrades
2023-2024
I upgraded a food-grade packaging machine to shrink-wrap bundles of ice cream pints together almost twice as fast as the previous design.
Motions are driven using servo motors, a precision rack and pinion, timing belt and pully, pneumatic cylinders, and linear rails.
Machine process is monitored by thermocouples, integrated encoders, induction sensors, diffuse light sensors, and thru-beam light sensors.
Heating elements splice, cut, and shrink-wrap plastic film.
2022-2023
I designed and developed two custom food-grade machines in Solidworks to automate intricate tasks that were previously done by hand.
After several prototypes, these machines were successfully fabricated, assembled, and integrated into the granola production line.
Motions are driven by inverter duty AC motors, a servo motor, and pneumatic cylinders.
The process is sensed by an integrated absolute encoder, induction sensors, and thru-beam light sensors.
Intrigued? Check out some of the project photos!
Upright Capsule Concept
Upright Capsule Concept
2023
This machine concept would to orient capsules onto a conveyor with their caps facing upward.
The process would utilize an AI integrated imaging system.
Automated Adhesive Applicaton
Automated Adhesive Applicaton
2022-2023
Conveyors shuttle pallets into the machine, where a 6-axis robot applies glue to the parts in a precise pattern.
The machine was successfully completed and installed at the customer's site.
Check out a video of this machine in operation!
Etching Machine
Etching Machine
2021-2022
I designed a machine for etching patterns onto the surface of steel cylinders using high voltage and an electrolyte liquid solution.
This projected was successfully completed and is still in operation.
Motions are driven by a controller-integrated step motor with a lead screw and a pneumatic cylinder with a linear cam.
Motions are tracked by an absolute encoder inside the motor and proximity sensors.
Laser Marking Machine
Laser Marking Machine
2021
I designed two machines that integrate a 4-axis robot with a CO2 laser marker.
Scroll down to the next section to see a customer comment about how satisfied he was with this project.
2020-2021
Undergraduate research with the Center for Biofilm Research at Montana State University.
I simulated the fluid dynamics inside a CAD model of the CDC Biofilm Reactor to analyze the best conditions for optimal biofilm growth.
Want to melt your mind with technical jargon? Check out the paper we published!
2016
My high school Supercomputing Challenge & Science Fair project.
I modeled our solar system and the Lorenz Attractor using Python, quantifying the chaos in each system.
I was a finalist at the 2016 International Science & Engineering Fair.
Check out the project deets & animations I created!
Endorsements
Endorsements
Theo,
I wanted to let you know that working with you (Theo) on this Laser Marking project exceeded my expectations. You were quick to answer any questions I had, and you did a great job communicating the project progress. The management team appreciated the detail you put into the several project meetings we had. I have no doubt that your thoroughness will make this a turn key machine when it arrives at our site.
It was a pleasure to have you as the lead design engineer and main point of contact for this large project.
-Joshua Darling, Automation and Controls Engineer II at Revision
Creative Projects
Creative Projects
Magazine article collab with Finn Beidleman
Fisheye Mountainscape - created in Adobe Illustrator
Portable wind tunnel used for wind power education
Remote controlled robot made from a salvaged electric wheelchair
Bike shelter made from salvaged wood
Page updated
Google Sites
Report abuse