Engineering Design Portfolio

2022

USA MAP Puzzle Rendering

  • I created 56 SolidWorks parts to capture 50 states and associated islands.

  • I rendered the assembly.

US Map Assembly2.mp4

Semi-Octet Trusses for &Spacecraft

  • We created a manufacturing standard for &spacecrafts to allow people from all over the world to produce these structures.

  • I welded components used in the trusses, as part of the Manufacturing Team.

2021

Learning Factory Retrofitted Vending Machine

  • Given a 1997 cash-and-coin vending machine, the team updated it to include LEDs, a touch screen GUI, and Penn State ID compatibility.

  • I worked on the GUI using Python's Tkinter and prepared a user manual. Our software team, under my leadership, programmed the GUI and server-vending machine communication.

Heels-to-Flat Mechanism Lamina Emergent Mechanism (LEM)

  • LEMs are a special subset of compliant mechanisms that are planar and conform to/deploy from a flat surface.

  • This project aimed at investigating the feasibility of applying LEMs to footwear.

  • Compared ANSYS simulations's max deflection and to manufactured prototypes.

  • We conducted market research through Idea Launchbox, Penn State's idea incubator.

  • I presented our research at the Penn State College of Engineering Research Symposium (CERS) 2022, where we won 2nd place.

Compliant.mov

Material Extrusion Lamina Emergent Mechanism Validator

  • This algorithm determines LEM printability with respect to restrictive Design for Additive Manufacturing (DfAM) parameters.

  • I conducted experimentation with PLA, TPU, and PETG to realize elements of restrictive DfAM and built the tool using Microsoft Excel's data vaildation tool.

DfAM Video Sumitted.mp4

Iron Lion Design Challenge 2021 - PowerPlant

Akash Dhotre, Evelyn Thomas, Palmer Dick-Montez

  • I competed in the Iron Lion Design Challenge (hosted by Penn State) with Akash Dhotre and Palmer Dick-Montez. Fifteen teams signed up for the competition, which spanned July 28-July 30.

  • The prompt was "Build something to help someone somewhere." We decided to help people and plants. Our system allows users to interact with plants and plants to communicate their needs (water, sun, humidity change) with humans.

We tied for Best Design (1st place)!

2020

Mount Ranier Scale Models

COVID-19 has separated many from their loved ones and caused many others to forgo vacations in 2020. Using Terrain2STL, I brought a bit of the Pacific Northwest to me. The summit of stratovolcano Mount Rainier is the tallest peak in Washington State. I isolated the mountain to obtain the STL file (Figure 1) and used Slicer For Fusion 360 to slice in 3 different orientations - stacked slices (Figures 2.1, 2.2), interlocking slices (Figures 3.1, 3.2), and radial slices (Figures 4.1, 4.2). I used a Cricut Maker to generate cardstock slices. The radial slice allowed for easiest assembly, though the interlocking slices kept the most fidelity to the STL file. The stacked slices should only be used with foam board or craft wood, instead of heavy cardstock, for greater depth.

2019

UT Tower Scale Model

  • Modeled the University of Texas at Austin’s famous Tower in Autodesk Fusion 360 from 137 year-old classified schematics to

  • Completed my Advanced Design and Manufacturing certificate

  • 3D Printed interlocking parts using Fused Deposition Modeling

  • Wired light strips (Neopixel breakaways) and programmed light sequences with user-designed parameters with Arduino

  • Consulted with Graduate advisor on the self-paced, self-funded project and presented machine tolerance research

I presented my research on machine tolerances and the accuracy of converting the 2 blueprints I had access to, into parts that could be assembled. I used calipers to get measurements, determined a scale factor, and transferred line-by-line into AutoDesk Fusion. From there, I printed as a .stl file.

The top portion of the UT Tower involved many details and vectors. After reflecting the image to get 1/4th of the top of the tower façade, my personal computer as well as university computers froze. Autodesk Fusion crash on my computer. SolidWorks crashed on the university computers.

Neopixel breakaways wired, powered by Arduino

Top Dead Center Sensor

  • Sensors were needed to detect Top Dead Center on 3 UT Austin Mechanical Engineering Dept. engines: GM Diesel, Single Spark Ignition Engine, and a Cummins 3.9L engine.

  • Machined parts and collaborated to produce $10,000 top dead center engine sensors for $150

  • Presented project deliverables to senior faculty and graduate students of the Mechanical Engineering department

2018

Semi-autonomous shopping cart

  • Collaborated with a team to produce a semi-autonomous shopping cart

  • Laser cut, designed parts in SolidWorks

  • Assisted with motor and Arduino wiring for semi-autonomous shopping cart

  • Lightweighted cart frame using laser cutting without compromising its ability to hold an adult human

video-1602214355 (1).mp4

Mechanical Vice Machining

Brass flat pieces were CNC machined. Steel pieces were machines on the mill and finished on the grinder. The screw piece faced, turned, and tapped, on the lathe. The brass knob was turned, faced, knurled, fill chamfered, on the lathe.

video-1602214344 (1).mp4

CNC Machined Graduation Name Plate

Designed using SolidWorks and converted to GCode using the CAD to CAM software within SolidWorks. This served as a graduation gift and part of my M E 350 grade. A portion of the text has been censored to maintain the privacy of the recipient.

Remote-Controlled Car

● Laser cut parts, performed motor and torque calculations

As Team #3, our car made it to the finals. After an unfortunate non-performance-related crash, it placed 4th place out of 32 team cars.

video-1602459238.mp4
video-1602459212.mp4

2017

Wearable Ketosis Monitor CAD Concept

● Created an exploded diagram and BOM using SolidWorks for a theoretical wearable Ketosis monitor

● Pitched the deliverables for the group project to convey mastery of engineering communications

2016

3D Printed Stapler Frame

Printed parts based on dimensions obtained from measuring the stapler parts with calipers. Parts were designed in SolidWorks and hand drafted according to GD&T standards.

Stapler parts for reverse engineering

2015

Smartphone Microscope

● Engineered smartphone microscope that outperformed models at 62%-67% of cost

I worked on Methods B and C. Method B involved force-fitting the lens into a 3D-printed outer cartridge. The cartridge was intended to be attached to the phone; however due to the flash being blocked by the cartridge, a redesign was needed. Method C involved 3D printing an iPhone case and sawing it in half. Sawing it allowed for it to be used for other iPhones that were longer or shorter. The lens was fit into a rectangular piece with an additional hole drilled for the flash.


Our Smartphone Microscope:

Top image: gum wrapper

Bottom image: Computer screen

Right: Salt

Commercial Smartphone Microscope:

Left: Blonde hair

Right: Printed text

Other Freshman Projects

One of the biggest selling points of The University of Texas at Austin was the "Longhorn Makerspace" (now "Texas Inventionworks"). As a first semester freshman, I was trained on using the FDM 3D printers, laser cutters, plasma cutters, and sewing machines.

One of my first 4-hour-long laser cutter projects involved this Pittsburgh Steelers themed wood piece. I laser cut the picture and used Retina Engrave to add the Super Bowl #s and years. Next, I painted over it to make it pop.

My dad's laser cut and painted Father's Day gift.