Engineering Projects

Antenna Winding Station

MADE WHILE WORKING AT VELATRON TECHNOLOGIES

Sept 2025 – Dec 2025

What
Converted an existing pneumatic roller machine into a reliable, multi-purpose antenna winding station for production use.

How

Upgraded the pneumatic system to improve consistency and control

Designed custom tooling and fixtures to support antenna winding operations

Integrated an electrical warning and braking system for operator safety

Developed precision cutting jigs achieving ±0.008” tolerances

Defined the manufacturing technique and created step-by-step production documentation

Outlined improvement roadmaps and next steps for future co-op students

Result

Enabled future scalability toward high-volume manufacturing

Delivered a production-ready machine suitable for repeat use

Improved process reliability, safety, and dimensional accuracy

To see all projects done with Velatron, click here

HiPot Testing Enclosure

MADE WHILE WORKING AT VELATRON TECHNOLOGIES

Oct 2025 – Dec 2025

What
Designed and built a reusable high-voltage safety enclosure for hipot testing in a production environment.

How

Collaborated with electrical and manufacturing engineers to integrate the enclosure into an existing electrical safety box system

Researched applicable high-voltage safety requirements and best practices

Independently designed, machined, and assembled the enclosure

Integrated electromagnetic safety interlocks to prevent operation when open

Added gas shock mechanisms for controlled, ergonomic opening and closing

Designed and 3D-printed a PC-FR insulating base to improve electrical isolation

Result

Rated for electrical testing up to 20 kV

Deployed as an active production tool in manufacturing

Improved operator safety and standardized high-voltage testing procedures

To see all projects done with Velatron, click here

Autonomous Sumo Robot 2.0

April 2024 – June 2024

What
Designed and built an autonomous Arduino-powered sumo robot to detect, engage, and push opponents out of the ring in compliance with competition rules.

How

Designed a custom 3D-printed chassis with integrated mounting for sensors and actuators

Used an Arduino as the primary control system, powered by a 9V battery

Supplied the motor driver with dual AA battery packs for reliable drive power

Implemented opponent detection using ultrasonic (hypersonic) and Sharp sensors

Integrated line detection using a superbright LED and phototransistor

Added a servo-driven automated platform deployment mechanism

Programmed an LCD interface to display real-time robot states (e.g., ATTACK, FINDING) based on sensor input

Result

Delivered a competition-ready robot with optimized performance and feedback visibility

Achieved reliable autonomous detection, decision-making, and engagement behavior

Demonstrated robust sensor integration and power management

OMEGA Wire Press

MADE WHILE WORKING AT VELATRON TECHNOLOGIES

Mar 2025 – Apr 2025

What
Led the redesign of a coil finishing process to support high-volume production of bent wires for a large manufacturing order.

How

Evaluated existing 90-degree wire bending methods and identified scalability limitations

Reviewed the full coil finishing workflow with engineering and production teams

Proposed an omega-shaped wire bend to enable faster forming, finishing, and cutting

Designed and built a press-style jig inspired by cookie-cutter manufacturing

Conducted cost and material waste analysis to validate production viability

Result

Enabled efficient production of 20,000+ units with improved ergonomics and throughput

Reduced coil finishing time from 5 minutes to 3 minutes per unit

Eliminated the primary production bottleneck in a process unchanged for over 15 years

To see all projects done with Velatron, click here

Final Bending Jig

First Iterations of the 90-degree Bending Jig and First Attempt at Omega-Shaped Bending Jig

Spiral Coil Jigs

MADE WHILE WORKING AT VELATRON TECHNOLOGIES

Mar 2025 – Mar 2025

What
Developed a production process and tooling to form a precision wire winding for a medical machine application.

How

Interpreted customer-supplied drawings with extremely tight tolerances

Rapidly prototyped multiple jig designs within a one-week timeline

Evaluated bend accuracy and repeatability across different configurations

Finalized a three-jig forming system to achieve the required geometry

Revised original drawings to adjust tolerances for manufacturability while preserving function

Submitted updated drawings to the customer for review and approval

Result

Balanced precision, efficiency, and manufacturability under a tight deadline

Established the standard production method for this component

Achieved consistent, repeatable wire geometry within medical-device requirements

To see all projects done with Velatron, click here

Simon Says Game

Sept 2023 – Nov 2023

What
Designed, manufactured, and programmed a “Simon Says” game capable of progressing through 30 levels, inspired by the classic SIMON game.

How

Designed a custom Arduino shield PCB using ExpressPCB
Fabricated the PCB, including precision drilling using a drill press
Populated and soldered all electronic components to complete hardware assembly
Programmed the game logic in the Arduino IDE to generate and validate random light-and-sound patterns
Integrated buttons, LEDs, and audio feedback for interactive gameplay

Result

Combined reliable electronics design with engaging, user-facing functionality

Delivered a fully functional, standalone electronic game

Demonstrated end-to-end hardware and software integration

Horizontal Dremel Grinder

MADE WHILE WORKING AT VELATRON TECHNOLOGIES

Feb 2025 – Mar 2025

What
Prototyped a method to precisely remove excess tinned wire flush to a part surface within extremely tight tolerances.

How

Evaluated conventional cutting methods and ruled them out due to risk of component damage
Collaborated with the engineering team to identify grinding as the most viable approach
Designed a custom jig to control wire feed depth and stop position before surface contact
Integrated a precision rotary tool (Dremel-style) to achieve sub-millimeter accuracy
Iterated over multiple prototypes using 3D-printed parts, scrap wood, and repurposed materials

Result

Documented limitations and proposed design improvements for future high-volume production

Achieved reliable wire removal within ±0.1 mm tolerance for sample production

Delivered a low-cost, functional setup suitable for producing initial customer parts

To see all projects done with Velatron, click here

Transformer Wrapping Jig

MADE WHILE WORKING AT VELATRON TECHNOLOGIES

Jan 2025 – Feb 2025

What
Designed a custom jig to assist production workers in wrapping wire around transformer cores accurately and efficiently.

How

Designed a jig that elevates and secures the core, enabling smooth wire threading from both the top and bottom
Integrated a telescopic end holder to anchor wire at a precise distance for consistent length control
Iterated on multiple prototypes to resolve issues with holder stability and fork height
Added adjustable levelers to accommodate multiple core sizes
Fabricated components using 3D-printed PLA, repurposed materials, and scrap wood to minimize cost

Result

Reduced wrapping time from 20 minutes to 15 minutes per unit

Improved repeatability and ease of use for production workers

Enhanced workflow efficiency for a time-sensitive transformer order

To see all projects done with Velatron, click here

Final product

First iterations/prototypes for the jig

Wire “Salad Spinner” Jig

MADE WHILE WORKING AT VELATRON TECHNOLOGIES

Jan 2025 – Jan 2025

What
Redesigned the wire-wrapping process to produce consistent, tangle-free wire lengths for production use.

How

Identified inefficiencies in the manual spool unwinding and rewrapping process
Prototyped multiple 3D-printed designs to automate and standardize wrapping
Designed a threaded sliding ring with guided ridges in SOLIDWORKS for precise coil spacing
Replaced unreliable mechanical counters with visual reference markers for repeatable lengths

Result

Reduced wire-wrapping time from 8 minutes to 3 minutes per unit

Eliminated tangling and length inconsistencies

Improved throughput and reliability for high-volume production

To see all projects done with Velatron, click here

Final Product

First iterations

Conveyor Belt Tensioner

Mar 2025 – Mar 2025

What
Designed and built a belt tensioner for a custom conveyor system used in the manufacturing of a specialized part.

How

Designed the tensioner and full assembly in SOLIDWORKS
Salvaged linear ball bearings and steel rods from decommissioned equipment to reduce cost
3D printed prototype components to validate fit, motion, and alignment
Reviewed the design with a senior engineer before finalizing
Delivered final CAD files to a machinist for future fabrication

Result

Enabled smooth belt tracking and readiness for long-term production use

Produced a cost-effective, robust belt tensioning solution

To see all projects done with Velatron, click here

Autonomous Sumo Robot 1.0

April 2023 – June 2023

What
Developed the first iteration of an Arduino-powered sumo robot for a competitive push-out robotics challenge.

How

Designed and fabricated a custom chassis from scrap plastic using heat forming techniques
Designed a custom PCB shield to integrate line detection using a superbright LED and phototransistor
Implemented opponent detection using an ultrasonic (hypersonic) sensor
Integrated a motor driver for precise speed and directional control

Result