threeRivers3d

9/2016 - Present

Mechanical Lead

Sept. 2016 - Present

 In charge of current and future research and development of 3d scanners and accessory hardware.  Worked with customer, production, and vendors to create a stand-alone kiosk for chiropractic waiting rooms.  This spanned from initial concepts and hand built prototypes to refined parts from vendors.  This was accomplished in conjunction with our production coordinator, assembly technicians, and software department to bring it to fruition.  This process spanned 4 months, when the first few units were shipped out of the facility.  Once in production, the task of dealing with vendor issues as they arise to keep units being built and up to quality standards.  While keeping up with these issues, I led efforts to bring manufacturing of our part with the highest scrap rate in-house.  This involved spec'ing out a small CNC router, assembling it, testing its limits, and designing the required fixtures to machine this part.  In conjunction with the software department, I designed and built an automated calibrationstation that would allow the calibration and verification of a scanner engine in one location.   A modified Stewart-Gough platform was designed and 3d printed to allow for robust calibration along with a linear rail for the engine to move through the different steps involved.  These two projects were never fully finished due a change in company leadership.

Responsibilities:

  • Mechanical Research and Development
  • Personally Prototyping, Concepts
  • Designing Parts in CAD (Onshape / Solidworks)
  • DFM / DFA to keep part costs down
  • Creating Drawings and Maintaining Revision Control (Onshape / Solidworks ePDM)
  • Sending new parts or revisions out to vendors for quotes
  • Working with the team to find and vet new vendors
  • Coordinated with production to solve problems as they were found while assembling products

Skills Acquired:

  • Building, Calibrating, and Using 3D Scanners
  • Simplifying Production with COTS parts
  • Thermoformed Plastics Design
  • CNC operation
  • CAM basics
  • Performing R&D on a small budget
  • Manufacturing Locally
  • Calibration and Assembly in-house
  • Important Vs. Urgent priority of tasks

4moms Self-Installing Infant Car Seat

8/2012 - 6/2016

4moms_ics.png

Technical Lead

Jan, 2016 – Jun, 2016

Brought the car seat from engineering prototype to pre-production.  Contributed and managed the continued development of the Self-Installing Infant Car Seat. This involved continuing to collaborate daily with Industrial Design, Marketing, Supply Chain Engineering, and Quality departments.  Lead the team to assure modifications were made to improve the quality of the mechanisms while in development.  Communicated with the manufacturer about said modifications and if they were possible and cost effective.  Participated in trips to contract manufacturer in China to solve issues with the production process and manufacturing. Organized multiple trips to crash testing facilities for multi-day testing, as well as heading each trip to ensure success.

The base leveling and tensioning

The base leveling and tensioning

Mechanical Engineer

Aug, 2012 – Jan, 2016

Participated in New Product Development for Self-Installing Infant Car Seat team.  Helped develop new mechanisms to achieve a car seat that could install itself. Began with a small override mechanism, graduated to a custom designed plastic gearbox, and ended with full ownership of the project when promoted to Technical Lead.  This position included wholly owning a subsystem and iterating it until it was ready for production.  The team followed an agile approach to hardware including daily stand-ups and weekly meetings to communicate where each team member was with their focus area.

Responsibilities:

  • Conceptualizing new mechanisms/solutions
  • Designing the mechanism in CAD (Solidworks)
  • Defining test methods for said design
  • 3d-Printing and testing the new design
  • Identifying problems/interferences/issues
  • Iterating design based on identified issues
  • Releasing finalized designs for manufacture
  • Refining designs once in manufacture based testing
  • Handing over project to supply chain after production start

Skills Acquired:

  • Project Leadership
  • Conceptualizing
  • Parametric Design
  • Equation Driven Sketches - Solidworks
  • Surfacing - Solidworks
  • EPDM - Solidworks
  • Design for Manufacture - Plastics, Sheet Metal, Extrusions
  • Plastic Part Design
  • Design for Assembly
  • Communication with Contract Manufacturer
  • Design of Experiments - Testing newly designed mechanisms

Patents:

 
 

WVU Lunabotics - NASA RMC 2012

The NASA Robotic Mining Competition (formerly Lunabotics) is a competition where university level students design and build a mining robot that can traverse an simulated off-planet environment and mine a basaltic regolith simulant.  

The team consisted of 12 masters and bachelors level students.  Work began in September of that year to research previous designs and brainstorm ideas for digging mechanisms and locomotion.  Immediately after designs were outlined and planning began.  Purchasing and fabricating components then initiated.  Along with this testing was conducted up until the date of competition.  The competition was held at the Visitor Complex at Kennedy  Space Center.  The team placed 10th overall.

 
 

WVU Lunabotics - NASA RMC 2011

The NASA Robotic Mining Competition (formerly Lunabotics) is a competition where university level students design and build a mining robot that can traverse a simulated off-planet environment and mine a basaltic regolith simulant from a remote location.   

2011 marked the formation of the WVU team.  It consisted of 12 masters and bachelors level students.  Work began in September of that year to research previous designs and brainstorm ideas for digging mechanisms and locomotion.  Immediately after designs were outlined and planning began.  Purchasing and fabricating components then initiated.  Along with this testing was conducted up until the date of competition.  The competition was held at the Visitor Complex at Kennedy  Space Center.  The team placed 3rd overall.

 
 

3d Printers

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Started researching in 2009
Acquired first Reprep Prusa Kit 2011
Upgraded to Printrbot Simple Metal 2014
Experienced with numerous printers:

  • Repraps
  • Printrbot
  • Uprint
  • Uprint+
  • Fortus 400mc
  • Objet 30

 


ELECTRIC MOTORCYCLE CONVERSION

SENIOR PROJECT 2009

Project Lead / Engineer

For our senior project we decided to take on the task of converting a used gasoline motorcycle to electric for the minimum cost using commercial off the shelf components.  The team consisted of four engineers from the mechanical engineering department.  The bike was completely researched and designed in the first semester.  Then the components were bought and the bike was built the second semester, finishing during finals week.

Project Statement:
The purpose of this project is to convert small vehicles that are used frequently, such as motorcycles, over to electric to reduce reliance on petroleum fuels and slow global climate change.

This project was focused on the final goal of converting a gasoline motorcycle that will be used for local commuting with a range that covers the average commute, which is around 20 miles. This will also be based on the assumption that this will not be the primary vehicle for the end user. It will be a vehicle for daily commuting or short trips.

Features:

  • Concept to Driving in 2 semesters.
  • Total cost of $2100
  • Range of 25 miles
  • 19 hp peak
  • 48v x 50Ah SLA Batteries
  • Charge time 8hrs with built in charger
  • 4 Person Team

 

 
 

BAJA SAE TEAM

WVU TECH 2007

Project Lead / Engineer

The SAE team at WVU Tech had competed in this design competition in previous years but due to the rules, either a new vehicle must be built or a previous vehicle must be heavily modified.  Our team decided to go the scratch route.  This consisted of designing, fundraising, obtaining the required materials, getting the proper tools, and then actually building it.  We accomplished this task in under a year.   During this process I organized meetings, recruitment, email, website updates, and participated in fabrication.

Baja SAE consists of competitions that simulate real-world engineering design projects and their related challenges. Engineering students are tasked to design and build an off-road vehicle that will survive the severe punishment of rough terrain.

The object of the competition is to provide SAE student members with a challenging project that involves the design, planning and manufacturing tasks found when introducing a new product to the consumer industrial market. Teams compete against one another to have their design accepted for manufacture by a fictitious firm. Students must function as a team to not only design, build, test, promote, and race a vehicle within the limits of the rules, but also to generate financial support for their project and manage their educational priorities.

  • Designed Fall 2007
  • Built Spring 2008
  • 10 HP Briggs and Stratton Engine
  • Hand-built Chrome-Moly Frame
  • Competed in May 2008 in Montreal, Canada
 
 

Small Projects



Meteorite Containment Giftbox

2017

Hackaday_2017.png

Somy wife's birthday was coming up and I had not found the perfect gift for her. I was sitting around browsing the internet when it hit me that she would love to have a meteorite. I tracked down a site to buy them and found a reasonably priced one. I realized that while the space rock is cool, it doesn't have a whole lot of charm. I then set out to figure out how to put some excitement into this gift. After a little brainstorming, I came up with the idea of a gift box for it. The meteorite originally impacted in Russia, so I crafted the box around the theme of space age Russia. Knowing my theme I then found a nicely vintage (beat up) sheet metal box on Etsy and ordered it and the meteorite. 

The build consists of:

  • 1 Arduino Leonardo
  • 2 haptic motors
  • 1 9v battery 
  • 1 3d printed cone
  • 23/8" hand-bent aluminum rods
  • 1 vintage film reel box
  • 1 1/8 piece of walnut
  • 1 neopixel ring
  • 1 rocker switch
  • 1 piece of aluminum


Overall it ended up costing around $120, I purchased the meteorite, box, magnet, and aluminum parts. The rest I had laying around. 

Video of the box being opened: https://goo.gl/photos/TiSMk6z


Particle IOT Button

2016

This is an internet button I built using a particle photon4 AAA batteries, a gigantic sparkfun button, and a 3d printed housing.  I use it to turn off a light that is connected to my smartthings hub.

The particle stays in deep sleep mode until it is woken up by the button press. It then publishes an event called Button, waits a half second to make sure the event was sent, then goes back to sleep.

Since the board is asleep 99% of the time, the normal ifttt channel for Particle doesn’t work, it relies on a heartbeat signal that it can’t respond to. Therefore the maker channel has to be used where it looks for a post request from a generic device. 

The instructions on how everything is setup are available at hackaday.io/project/13080-iot-button.

 
 

Created in 2010 and has been growing since.

 
 

NESPi

2016

3d Printed Case
Finished / Painted
Retro Bluetooth Controller
Raspberry Pi 2
RetroPie OS
Runs: Commodore, Atari, NES, Super Nintendo, Sega Genesis, N64 Emulators

 
 

Arduino Workshop Presentation

2015

Arduino workshop developed to inform coworkers of the attributes of the arduino family of microcontrollers and programming language.  This is designed to be a quick crash course into the arduino environment without being  overloaded in details.  It's a quick reference so the viewers can grasp what the platform is capable of.  The viewer can then use this as a starting point to further research how to accomplish the goals of their project by using the included links. The presentation is broken down into three parts.  

 


Airplay Speaker

2013

I built an AirPi Wireless Speaker.  It consists of a raspberry pi, small amp circuit, powered usb hub, wifi adapter, bookshelf speaker, and a usb battery.  

You simply turn it on and wait for it to boot up then you can play music from your itunes or iphone using airplay.  I also have mpd and mpc installed so that androids can play music on it too.

 
 

Wrench Coffee Cup

2014

Wrench Coffee Cup - Shapeways
This is the ceramic coffee cup I designed for my dad for christmas  in 2014. The mug is the shape of a hex nut with a bent wrench as the handle.  The inside of the mug has the boxend of the wrench poking through.

 
 

Voice Launcher

2012

Built it in C# and  uses the .Net framework and Speech SDK.  By clicking start the program started listening for the text in the name field, then listened for "open, run, or start" a command that was in the user defined list.  This was back before siri, cortana, or ok google.

 Features:

  • Keyword and location adding
  • Deleting of added keywords along with shortcuts
  • Saving created lists
  • Loading saved lists
  • Naming of computer
  • Run, Open, or Start opens a program
  • Exit, Kill, Close stops a program*

*it killed all programs named that

 
 

MP3 Player

2011

My mp3 player.  I built it out of a Sparkfun box, Sparkfun serial 16x2 lcd screen, Fez Domino microcontroller, mp3 shield, 4 x AA batteries, and some buttons and switches.  It ran C# code.  The aluminum case was built from scrap during Lunabotics.

Features:

  • LCD screen
  • text based UI
  • 3 button interface
  • sd card for mp3 files
  • files on sd card
  • play / pause button
  • next track button
  • previous track button