Projects with Velatron (WINTER/FALL 2025)

Antenna Winding Station

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

HiPot Testing Enclosure

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

Tube Guillotine

Feb 2025 – Apr 2025

What
Designed and built a high-efficiency tube-cutting “guillotine” to streamline material preparation in high-volume production workflows.

How

• Designed a spring-loaded handle to provide fast recoil, reducing cycle time and operator strain

• Machined an aluminum baseplate to support the jig and guide tubing smoothly into the cutting zone

• Designed and integrated a custom-machined blade for clean, precise cuts through plastic tubing

• Added a gravity-fed drop system to route cut tubing directly into a collection basket

• Integrated a transparent plexiglass safety cover with dry-erase measurement markings for quick size changes

• Included an adjustable stopper to ensure repeatable, consistent cut lengths

Result

• Delivered a durable, production-ready tool that reduced manual handling

• Significantly improved speed and ergonomics in material preparation

• Increased cut accuracy and repeatability for high-volume workflows

Machine Ventilation

Apr 2025 – Apr 2025

What
Designed and implemented a custom intake ventilation system to address recurring overheating in a production machine.

How

• Analyzed airflow limitations contributing to premature machine failure

• Engineered a fan-based intake system that activates only during machine operation to improve cooling efficiency

• Drilled into the stainless-steel frame and designed a custom mounting solution

• 3D printed a precision-fit bracket to securely mount the fan and ensure long-term stability

• Directed airflow toward internal components most susceptible to thermal stress

Result

• Potential to extend machine lifespan and reduce six-month repair/replacement cycles

• Improved internal airflow and temperature regulation

• System currently operating in production for performance validation

OMEGA Wire Press

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

Spiral Coil Jigs

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

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

Horizontal Dremel Grinder

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

Chemical Cup Holder

Jan 2025 – Jan 2025

What
Designed a spill-prevention holder to stabilize chemical cups used at a high-temperature soldering workstation.

How

• Assessed spill risks caused by confined workspace geometry and cup instability

• Designed a wide-base holder to securely capture and support the chemical cups

• 3D printed the holder in PLA for rapid deployment

• Split the design into one-cup and two-cup modules due to build-plate size constraints

• Integrated a puzzle-style joint to allow the modules to interlock securely

Result

• Delivered a low-cost, quickly deployable safety solution

• Eliminated chemical spills at the workstation

• Improved operator safety and confidence when handling chemicals

Transformer Wrapping Jig

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

Spool Cap Tightener

Jan 2025 – Jan 2025

What
Designed a simple add-on to stabilize wire spools during unwinding and reduce excess tension in the wire-wrapping process.

How

• Identified spool movement as the source of inconsistent wire tension

• Designed a truncated cone tightener with internal threading to fit into the spool core

• Secured the spool directly to the turntable to prevent shaking and lateral movement

Result

• Created a reusable solution applicable to future wire unwinding and cutting tasks

• Eliminated spool shifting and uneven tension during unwinding

• Improved smoothness and consistency of wire feed