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From $20 Lego sets to $2,000,000 Additive Manufacturing machines, I've always had a passion designing and building. There's nothing like instant tangible feedback to your ideas. Additive technology is quickly speeding up to meet our dynamic and expansive designs from custom cell phone cases to reusable rockets. Below are some of the highlights of my engineering work. Some are my personal designs while others are through previous work experiences.
MOTIV8 Trophy
This is by far my favorite design project, so much fun and I loved the challenge. Motiv8 Performance Center (MPC) is the gym that I have been going to for over a year now and I absolutely love it. Their logo is so simple and I thought it would be awesome to bring it into 3D.
Over the course of a couple months, I iterated through designs and prototypes, refining the look and feel of the trophy. The exploded view picture above is a great example of different manufacturing methods. From 3D Printing to Laser Cutting to CNC Machining, all three manufacturing methods were utilized.
I started by prototyping the 3D printed structures first, the most complex parts. The first prototypes were actually on my Airwolf 3D XL printer. As usual, I was impressed with the results as test components. Then I learned about Urban Workshop in Irvine, CA. It's basically a "gym" type membership to a machine shop. You can take classes to learn how to use the different equipment available to its members. I used their laser cutter to cut the acrylic plates on the front (red, gray). Then I 3D printed final versions of the structures on a Stratasys 3D printer. In this case, the material was Ivory White ABS, so eventually I sprayed them black with paint.
With all this plastic, I really wanted the structure to be stiff and strong. So the frame and the base are aluminum. With help from PRECISION / EXPEDITED, these parts were machined and anodized perfectly and on time. Always good to work with Rusty and his team. I later went back to Urban Workshop to etch the base plate, both with the Motiv8 logo (top) and my MilesIn3D logo (bottom). This was a great learning experience to be able to add features to a manufactured part.
Manufacturing Details
Laser Cutter @ Urban Workshop
Cut Acrylic Plates
Etch Aluminum Base
Stratasys Dimension Elite FDM Printer @ Urban Workshop
Print ABS 3D Structures
CNC Machining @ PRECISION / EXPEDITED
Cut Aluminum Base
Cut Aluminum Frame
Finishing @ MilesIn3D
Spray Paint Acrylic Plates Red/Gray
Spray Paint ABS Structures Black
Assembly @ MilesIn3D
Tapped 3D Printed Structures
Super Glued Plates to Structures
Pictures @ Cameron Williams
He did a magnificent job capturing all the subtle details of the trophy
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To finish off the project, I spray painted the front plates gray and red, then sprayed the structures black. To assemble it all together, I tapped the structures in the back to attach them to the frame. Then I super glued the plates to the structure and that was it! I am suuuuuper happy with the result!
And finally I presented it to the Motiv8 coaches and team and they absolutely loved it. My opinion of the Motiv8 Performance Center:
“MPC is so unique. The coaches are more than trainers, they’re role models. The athletes are more than friends, they’re family. It’s crazy how non-judgmental the atmosphere is. I am so grateful for the team that Kristin and J-Walk have put together.“
Changes I would make if I were to make it again (without money in mind):
3D Print the Red cover on a high end printer to get a fine finish as opposed to hand sanding
3D Print the structures in black, utilizing Carbon's CLIP technology for a better finish and stronger parts for such a complex shape
Stratonics IR Camera
Version 1
Spring 2014
As the additive process radiates heat from the melt pool, the cooling argon line keeps the IR Camera cool. This is important for keeping the a consistent and accurate signal.
Version 2
Fall 2014
The additive process is very active as it shoots highly energized particles out of the melt pool. This version of the case include a front plate to hold an IR Window. This allows the IR light to transmit through without allowing metal particles to hit the camera lens.
Version 3
Spring 2015
The added back cover keeps the electrical ports from getting in contact with floating metal powder that might short circuit the electronics.
Version 4
Fall 2015
This major design step change includes a machined aluminum chassis for added stability and improved integration. This case encapsulates the entire IR camera and accessories to keep the hardware clean.
Version 5
Spring 2016
This case was to be integrated into a Stratasys Fortus 380mc. The heated chamber demanded an increased in temperature resistance from previous applications. For this reason, the case material was upgraded from ABS to ULTEM 9085. This raises the Glass Transition temperature from 226C to 367C. Also, this means the cooling gas could not bleed into the heated chamber, so a second gas line adapter was added for purging the gas outside the machine.
Version 6
Fall 2016
This design incorporated the best features of the previous designs along with some nice additions. The chassis and two front plates were machined aluminum. A convenient upgrade was mounting holes on all sides allowing multiple integration configurations. The inlet and purge lines threaded straight into the chassis removing the tapping of the plastic housing operation. The plastic housing was printed with Carbon's Digital Light Synthesis (DLS) technology for a smoother surface finish and more accurate small features.
Airwolf 3D - HD Printer & Print Head
HD Printer Series
As the Lead Engineer at Airwolf 3D, I played a major role in the design of the HD series of printers. I worked on the design, prototyping, material testing and assembly. It is currently patent pending. The series includes the models HDL, HD, HDx, HD2x and HDR.
Specifications
Technology = Plastic FDM
Build Volume = 12" x 8" x 12"
25+ different printing materials, from PLA to ABS to PC
Remote/Wireless Printing
[November 2013 - February 2015]
JR Print Head Series
As the Lead Engineer at Airwolf 3D, I played a major role in the design of the HD series of printers. I worked on the design, prototyping, material testing and assembly. It is currently patent pending. The series includes the models HDL, HD, HDx, HD2x and HDR.
Specifications
Technology = Plastic FDM
Build Volume = 12" x 8" x 12"
25+ different printing materials, from PLA to ABS to PC
Remote/Wireless Printing
[November 2013 - February 2015]
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