Engineering Projects

OMEGA Wire Press

Mar 2025 – Apr 2025

I was initially tasked with developing a method to mass-produce 90-degree bent wires for a large production order of over 20,000 units, each requiring two bent wires for manual coil finishing. After several weeks of prototyping and testing various bending methods, it became clear that all options were inefficient at scale. Upon reviewing the full coil finishing process with the engineering and production teams, we discovered that the workflow hadn’t been optimized for high-volume production in over 15 years.

Working closely with the team, I proposed a redesign of the process by introducing an omega-shaped wire bend, which allowed for faster coil finishing and cutting after forming. I was given lead responsibility for developing a method to produce the new shape and designed a press system inspired by cookie-cutter manufacturing. Using an old lever press, I built a prototype jig from 3D-printed PLA and plexiglass, later finalizing the design in ABS plastic for durability.

In addition to designing the jig, I performed a cost and waste analysis to ensure the new method was viable for production. The final setup reduced coil finishing time from 10 minutes to 5 minutes per unit, significantly improving workflow efficiency and easing the burden on the coil finishing team, which had previously been the primary bottleneck in the process.

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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

I was tasked with developing both the process and tooling required to create a precise wire winding used in a medical machine application. The project involved working from general drawings provided by the customer, which included extremely tight tolerances. To meet the requirements within a one-week timeline, I prototyped a variety of jig designs to achieve the specific bends needed. After evaluating different configurations, I finalized a three-jig system that accurately forms the wire to the required shape. This process is now the standard method used for producing these components. I also revised the original drawings, adjusting the tolerances to make them more feasible for production while still meeting functional requirements, and submitted the updated version to the customer for approval. The final solution balanced precision, repeatability, and efficiency under a tight deadline, ensuring a reliable manufacturing process for a critical medical device component.

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Horizontal Dremel Mill

MADE WHILE WORKING AT VELATRON TECHNOLOGIES

Feb 2025 – Mar 2025

As part of a high-priority project, I was tasked with developing a method to precisely remove excess tinned wire from a part, flush to its surface. The tolerances were extremely tight, and the wire was located in a difficult-to-reach area—making it impossible to use conventional cutting tools or machines like a bandsaw without risking damage to the surrounding components. On top of that, the part was being produced in high volumes (around 100 units), so the solution needed to be both accurate and repeatable for production workers.

After collaborating with the engineering team, we decided that grinding the wire down—rather than cutting—was the most viable option. I proposed using a precision tool like a Dremel, mounted in place, combined with a custom jig that would allow the wire to be fed in and stopped just before touching the surface, staying within a 0.1mm tolerance.

After weeks of iteration, I built a setup similar to a horizontal, single-axis milling machine that could reliably grind the wire down to spec. The setup was assembled using a combination of 3D printed components, scrap wood, and other leftover materials like plexiglass. It proved to be a cost-effective and functional solution for producing the initial sample parts for the customer.

However, repeatability for mass production was still a challenge. While I’ve laid out documentation and suggestions for future improvements—including potential design changes to eliminate the excess wire entirely—I’m passing the project on to the engineering team and the next co-op student, as my term is wrapping up.

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Conveyor Belt Tensioner

Mar 2025 – Mar 2025

For one of the company’s projects, we developed a custom conveyor belt system to support the manufacturing of a specialized part. My role in this project was to design and build a belt tensioner that would keep the conveyor tight and running smoothly throughout operation.

To keep costs low, I salvaged parts from an old, broken machine and found nearly-new linear ball bearings and steel rods that could be reused. I designed the tensioner components in SOLIDWORKS and created an assembly, then 3D printed prototype parts to test fit and function with the salvaged components. After reviewing and confirming the design with one of the engineers, I sent the final CAD files to a machinist, who manufactured the parts in steel for durability and long-term use.

Although the conveyor belt will not be in-use until after the end of my co-op term ends, the parts seemed to work in the overall assembly and tests.

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Transformer Wrapping Jig

MADE WHILE WORKING AT VELATRON TECHNOLOGIES

Jan 2025 – Feb 2025

I was tasked with developing a tool to assist production workers in wrapping wire around a core for a specific transformer order. The jig I designed elevates and secures the part, allowing workers to thread the wire through the top and bottom efficiently. A telescopic end holder ensures the wire is anchored at a precise distance to meet length specifications.

Initial iterations faced challenges with the telescopic holder and sliding fork height. To address this, I redesigned and reprinted the main body to fit size requirements. Additionally, since multiple part sizes needed to be accommodated, I implemented adjustable levelers to modify the box height for a secure fit. The main components, including the box, telescopic holder, and levelers, were 3D printed from PLA, while the holder shaft was crafted from scrap wood. Other structural elements were machined from repurposed materials.

Ultimately, this jig reduced the wrapping process time from 20 minutes to 15, improving efficiency and workflow.

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Final product

First iterations/prototypes for the jig

Wire “Salad Spinner” Jig

MADE WHILE WORKING AT VELATRON TECHNOLOGIES

Jan 2025 – Jan 2025

As one of my first projects at Velatron, I was tasked with improving the wire-wrapping process for production. The original method required unwinding wire from a spool and manually rewrapping it, leading to inefficiencies such as tangling and the wire touching the ground. The goal was to create a system that produced neatly wrapped, tangle-free wire with consistent lengths.

In the initial design, I 3D-printed a cylindrical device with a sliding shell. The wire was wound by spinning the cylinder on a turntable connected to the spool. Once wrapped, the sliding shell was removed to release the coiled wire, which was secured with a zip tie. However, this version had flaws: inconsistent wrapping angles resulted in variable lengths, and the mechanical counter—constructed from scrap materials—failed to reliably track rotations.

After multiple prototypes and iterations, I developed a more reliable solution. Using SOLIDWORKS, I designed a threaded sliding ring with ridges to guide the wire for precise, consistent wrapping. Visual markers on the cylinder replaced the error-prone counter system, allowing workers to wrap at predefined points. This simplified the process and eliminated inconsistencies.

The final design reduced the wire-wrapping time from 8 minutes to 5 minutes per unit, significantly improving efficiency for high-volume production and saving valuable time for the team.

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Final Product

First iterations

Autonomous Sumo Robot 2.0

April 2024 – June 2024

Developed an Arduino-powered autonomous robot for a sumo competition, designed to adhere to sumo rules by engaging and pushing opponents out of the ring. The robot featured a custom 3D-printed chassis, with an Arduino serving as the primary control system, powered by a 9-volt battery. Dual battery packs, each containing AA batteries, supplied power to the motor driver. Advanced sensors, including hypersonic and Sharp modules, enabled opponent detection and engagement, while a superbright LED and phototransistor provided precise line detection. The robot also incorporated a servo motor for an automated platform-deployment system and an LCD screen to display operational statuses, such as “ATTACK” or “FINDING,” based on opponent detection via lidar sensors, ensuring optimized performance during competition.

Simon Says Game

Sept 2023 – Nov 2023

Designed, manufactured, and programmed an advanced version of the “Simon Says” game, capable of progressing through 30 levels, inspired by the classic SIMON game by Hasbro. The project included designing a custom Arduino shield PCB using EXPRESS PCB, fabricating the board, and drilling precision holes with a drill press. Electronic components were populated and soldered onto the board to complete the hardware assembly. The Arduino was programmed using the Arduino IDE to control the game, which challenges players to replicate randomly generated patterns of lights and sounds using corresponding buttons on the board, combining technical precision with engaging gameplay.

Autonomous Sumo Robot 1.0

April 2023 – June 2023

Developed the first iteration of an Arduino-powered sumo robot designed for a competition where the objective is to push the opposing robot out of the ring. The chassis was crafted from scrap plastic, shaped and manipulated using a heat gun. A custom PCB shield was created to integrate a line detection system utilizing a superbright LED and phototransistor. The robot featured a hypersonic sensor for detecting opponents and employed a motor driver for precise speed control, ensuring competitive performance.