Projects
Robotic Car Design
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Designed and fabricated a robotic car capable of traversing ramps and flat surfaces.
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Programmed a Raspberry Pi and processed http requests using Flask.
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Used HTML/CSS, JavaScript to create a webpage for users to control the car over the internet.
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Challenges:
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Maintaining a constant IP address of the Raspberry Pi.
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Creating smooth, and easily controllable turning.
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Providing sufficient torque to the car wheels without wall outlet access.
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Lessons Learned:
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Incorporated HTML/CSS and JavaScript.
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Used voltage divider to provide necessary voltages to microcontrollers and motors.
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BLACK+DECKER Drill Product Teardown/Redesign and CAD Modeling
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Examined use cases, concept of operations, and workflow of the product.
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Modeled relevant parts in SolidWorks to match drill
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Redesigned drill for Cerebral Palsy client using risk matrices and weighted down selection.
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Challenges:
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Creating SolidWorks models of shapes with unique curvature and profiles.
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Simplifying use requirements, without altering product feel or appearance.
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Lessons Learned:
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Worked with client in order to better understand design specifications.
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Recreated product CAD model without engineering drawings/dimensions.
Stepper Motor Gear Train
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Modeled a gear train to increase a stepper motor's output torque and decrease its output speed using OnShape.
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Fabricated gear train and housing using 3D printers and laser cutting.
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Programmed a Raspberry Pi to precisely control stepper motor.
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Challenges:
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Meshing gears together.
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Accounting for tolerances in 3D printed parts.
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Lessons Learned:
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Focused on gear train math in order to keep pitch constant between gears (allowed for gear meshing).
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4 Bar Linkage - "Auto-Pie"
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Designed a 4 bar linkage system, linkage/stepper motor housing, and "pie-holder" using OnShape.
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Fabricated components using 3D printers and laser cutting.
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Programmed a Raspberry Pi to precisely control stepper motor.
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Challenges:
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Keeping 4 bar linkage weight low.
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Providing enough torque to the linkage system.
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Restricting motion of 4 bar linkage into 1 plane.
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Lessons Learned:
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Designed CAD models with intention of lowering part weight.
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Laser cut bearings and spacers in order to keep linkage movement 2D.
Line Follower (Color Sensor)
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Used a color sensor to autonomously navigate a maze by following a specific color path.
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Programmed a Raspberry Pi using PID control to maintain correct path along colored paths.
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Fabricated chassis and wheels using 3D printers and laser cutting.
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Challenges:
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Consistency of color sensor readings.
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Providing sufficient light to color sensor.
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Finding the correct balance of proportional, integral, and derivative control in the overall PID controller.
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Lessons Learned:
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Focused on PID control to precisely control motion of a robot.
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Used color sensor Python libraries.
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Introduced to i2c controls within microcontrollers.
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Airtable Controlled Create 3 Maze Navigation
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Programmed a Raspberry Pi to communicate with the Create 3 over ROS2.
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Controlled a Create 3 robot’s movements by publishing and subscribing to the “/cmd_vel” topic in. combination with the geometry message type “Twist”.
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Used Airtable to request values that were input to publisher nodes.
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Challenges:
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Reading API key values so that they can be published to a topic.
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Publishing values correctly such that they can be read by the topic.
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Limited access to information on ROS2 topics.
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Lessons Learned:
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Used ROS2 to publish and subscribe to pre-existing topics.
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Requested API values from Airtable in Python.
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Autonomous Image Recognition Maze Navigation
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Programmed a Raspberry Pi to communicate with the Create 3 over ROS2.
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Published to Create 3 ROS2 topics "cmd_vel" and "cmd_audio" to control movement and audio of the Create 3.
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Trained a model using Google's Teachable Machine to recognize objects through a Raspberry Pi Camera.
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Challenges:
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Slow Raspberry Pi run time limited iteration capabilities.
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Raspberry Pi Camera field of view is small, making it challenging to view objects.
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Recognizing objects at a desired distance from the robot.
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Lessons Learned:
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Published to the "cmd_audio" ROS2 topic using the "AudioNoteVector" message.
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Processed Raspberry Pi Camera images to an image recognition model.
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Used model outputs to control publishing to ROS2 topics on the Create 3.
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Autonomous Smoothie Cafe
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Designed and fabricated components for "processing" and "blending" stations of cafe.
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Managed interactions with sponsors to integrate components into the overall project.
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Presented the smoothie cafe at the 2023 Robotics Summit & Expo.
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Challenges:
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Communication between project teams.
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ROS2 compatibility with iRobot Create3 robots.
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Managing budget.
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Limited access to metal working machines.
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Lessons Learned:
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Planning project scope such that goals are achievable.
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Communication between teams at all stages of a project is critical for success.
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Ensuring that others can follow your design process and can operate your creation.
Carbon Fiber Composite Baseball Bat
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Created a carbon fiber/epoxy layup to be wrapped around a 3D printed baseball bat mold, resulting in a carbon fiber composite baseball bat.
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Compared swing tests with ANSYS force simulations.
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Challenges:
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Limiting creases in the carbon fibers during the vacuum bagging process.
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Maintaining constant carbon fiber orientation within each layer.
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Preventing weak points in the final laminate due to lack of epoxy or carbon fibers in certain areas.
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Creating ANSYS simulations that represented the true loading conditions.
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Lessons Learned:
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Learned how to make complex geometries from composites.
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Worked with ANSYS to replicate real life loading condition.
Corn Hole Made from Repurposed Bike Parts
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Fabricated a corn hole set using bike parts and scrap steel.
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Cut bike parts using the portable bandsaw.
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Used TIG welding to make frame and legs of the corn hole set.
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Challenges:
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Finding bikes that were made from steel, not aluminum, so that they could be TIG welded.
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Removing paint from bike parts to avoid toxic fumes during welding.
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Lessons Learned:
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Improved TIG welding skills.
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Used new techniques to prepare bike parts such as the portable band saw and angle grinder.
Multi-Sample HTS Test Probe
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Designed a multi-sample high temperature superconductor (HTS) test probe to make HTS tape characterization more efficient.
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Created CAD models, CAD drawings, and bill of materials for several designs.
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Collaborated with other engineers to meet design requirements surrounding cryogenic capacity, material selection, and energy loss minimization.
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Challenges:
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Material/product behavior at cryogenic temperatures
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Optimization of ohmic losses and convective heat transfer across a temperature gradient.
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Minimization and repeatability of contact resistances
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Designing for manufacturability in a small, technologically limited machine shop.
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Part lead time.
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Limited prior knowledge about cryogenics and superconductivity.
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Lessons Learned:
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Designing for product robustness and reliability.
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Deeper knowledge of material property dependence on temperature.
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Fundamental understanding of cryogenic design and superconductivity.
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Worked closely with machinists to make CAD drawings and bill of materials.
Automated Clothes Tagging System
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Designed a system to improve upon the current manual tagging system for clothing identification in order to maximize efficiency and worker safety for immediate integration at Goodwill.
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Created CAD models, CAD drawings, and a bill of materials for various prototypes.
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Contributed to fabrication, mechanical analysis, and electrical/coding components of each prototype.
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Challenges:
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Geometric tolerancing on small, custom made parts.
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Designing for reliability.
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Preventing overheating of motors and drivers.
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Handling of flexible materials (fasteners, tags).
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Lessons Learned:
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Collaboration with other engineers for a long term project.
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Incorporating client requests into prototype design.
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Limitations of 3D printing for part fabrication.
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Managing budget.
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Designing for ease of assembly, usability.
Current Distribution Modeling in Superconducting Transmission Lines
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Created a foundational circuit model for current distribution within a high temperature superconductor (HTS) cable.
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Conducted an independent literature review on HTS circuit modeling.
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Worked with Tufts University professors and professional engineers to review circuit analyses.
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Challenges:
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Minimizing necessary calculations while providing accurate results.
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Acquiring data for testing model validity.
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Reviewing large quantities of relevant papers and textbooks.
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Lessons Learned:
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Reviewed electrical engineering principles.
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Learned the importance of simplifying mathematical models to reduce simulation time and required computational power.
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Conducted complex AC circuit analysis using mesh current method.
Iron Man Hand Lamp
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Fabricated a lamp using sheet metal and sheet metal bending.
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Utilized a water jet, a bending brake, and a spot welder to manufacture and assemble the lamp.
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Modeled the bends using Solidworks sheet metal tools.
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Challenges:
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Accurately bending sheet metal by hand.
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Limits on the weld thickness using a spot welder.
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Designing for assembly.
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Lessons Learned:
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Adding relief cuts to make sheet metal bending easier and to improve bend quality.
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Understand your materials’ properties well before designing.
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Consider how the product will be manufactured and assembled, not just the final product’s function.
Toy Race Car
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Used urethane casting to produce a toy race car.
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3D printed wheels and a chassis to serve as the master in the mold creation process.
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Fabricated a hard chassis and rubbery wheels from various urethane resins.
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Challenges:
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Minimizing voids and large air pockets in the casting process.
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Completing casts for parts with small thicknesses and unique geometries.
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Avoiding undercuts to ensure that the mold is reusable.
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Lessons Learned:
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Tilting the mold during resin curing can improve final part quality.
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High amounts of part detail can be easily replicated using urethane casting.
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Simplify part geometry to reduce undercuts and improve mold lifespan.
Puzzle Table
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Manufactured a flat-pack assembly style table using a CNC router.
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Designed the puzzle table to use only non-permanent joints such as slot, lap, and housing joints.
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Utilized VCarve to generate various CNC toolpaths.
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Challenges:
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Machining both sides of a piece of stock, leading to tolerancing issues.
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Fastening the stock without impeding the cutting tools.
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Limited sketching capabilities in VCarve.
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Lessons Learned:
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Learned how to program and preview toolpaths on a CNC router using VCarve.
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Simplify your geometry to avoid requiring excessive material removal.
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Consider the available cutting tools in your initial design.
Harry Potter Wand
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Machined a custom Harry Potter wand on a manual lathe.
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Experimented with several lathe fabrication methods such as turning, knurling, parting, and radius forming tools.
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Managed lathe rpm based on workpiece material for optimal results.
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Challenges:
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Manually feeding on a lathe produces inconsistencies in surface finish and part quality.
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Fastening the workpiece during machining to prevent chattering and deflection.
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Control wheel backlash resulted in difficulty making precisely measured turns.
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Lessons Learned:
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Learned how to set up and machine parts using a lathe.
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Use additional fixtures to completely fasten the workpiece during machining.
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Understood how to select appropriate feeds and speeds based on workpiece material.
