Manufacturing Processes: A sound knowledge of the processes for the creation of prototype and producton parts to include: SLS - SLA - Vacuum Casting - RIM - Injection Molding - Chemical Etching - Wire Erode - Casting - Sheet metal - Spark erosion - CNC.
Injection molding: Designed small functional plastic parts, and larger molded chassis’ parts for an Injection Mold. Working together with the tooling manufacturer to ensuring molds meet my functional requirements for structural feature stability. While reducing the complexity of the tool.
Molded chassis: Special considerations was also required for the chassis parts to maintain a minimum wall thicknesses, reduce sink marks, warpage and tool shut off positions in order to have a high quality external optical surface.
High volume Production: I have designed products with the MOQ in the thousands and alongside other design considerations, I was required to design with component and mechanism reliability, manufacturability and low component cost as a priority. While being constrained by established production assembly lines and volume manufacturing considerations.
DFM (Design For Manufacture): With well-established production lines in place, my new designs were constrained to existing off-site and in-house assembly line production processes, tools, infrastructure and skill set.
Manufacturer visits: I made frequent onsite visits to manufactures, overseeing the design of the parts and working very closely with them to understand their limitations and processes to ensure a more manufacturable design.
Machinist: Utilizing In-house Lath and Bridgeport Milling machines to make parts to aid me in prototype development and test.