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
Nolan Phuong 