Discover the projects that define my journey in mechanical engineering. This portfolio showcases a range of innovative designs, detailed analyses, and hands-on creations that demonstrate my ability to turn concepts into reality. Each project reflects my problem-solving skills and technical proficiency.
Design
Gear Train and Housing
A final project in machine design, where we were tasked to design a double reduction gear train and housing to reduce speed, increase torque all while carrying 10hp. Gears, bearings, retaining rings, and bolts were sourced from various online catalogs and imported. Shafts were designed using involute splines as a primary driving mechanism. To aid in design, an excel sheet was created to quickly iterate design features.
Flexible LED Lamp Design
This hands-on exploration of custom electronics and PCB design showcases the versatility of flexible LED strips in creating unique lighting solutions. The design features a modular approach that enables crafting various lamp shapes, demonstrated through a Gannon Shield configuration. The project involved practical circuit design elements, including resistor calculations and current specifications to ensure optimal LED performance and circuit protection. This foundational venture into PCB design and electronic component specification served as an excellent introduction to custom electronics fabrication.
Manufacturing
Brett Boyer Foundation
Developed and fabricated critical components for NFI’s Ford Highboy Roadster restoration project within a demanding one-week timeframe. Leveraged cutting-edge technology, employing Direct Metal Laser Sintering (DMLS) to 3D print both the rear differential cover and front emblem from 316 stainless steel. Precision machining complemented the manufacturing process. Notably, the components showcased the Brett Boyer Foundation’s logo, contributing to a successful auction that raised over $750,000 for Congenital Heart Disease research.
Bowtie
Commemorated the inauguration of Gannon University’s 8th president, Dr. Walter Iwanenko, by crafting a distinctive scale bowtie. The commemorative piece, distributed to the dedicated team behind the event’s success, reflected Dr. Iwanenko’s memorable mantra, “Always put on your tie.” Despite its non-functional nature, the project presented multifaceted challenges, including the intricacies of designing soft jaws, optimizing for manufacturing, precision machining of brass, iterative design refinement, establishing an efficient workflow, and navigating within stringent budget constraints.
Golfball Markers
Crafted a seemingly straightforward Christmas gift, unveiling unforeseen challenges in the process. Overcame obstacles such as selecting a suitable origin for milling and engraving post-turning, navigating the intricacies of turning brass on a potentially underpowered machine. The project underscored the importance of problem-solving and adaptability in achieving a successful outcome.
EFI Connection
Engaged in a comprehensive 13-week collaboration with Mike Noonan, focusing on the design and manufacturing of bespoke automotive components. This encompassed the development of innovative replacements for throttle bodies, timing cover assemblies, and a dedicated fixture plate for streamlined manufacturing processes. The projects were executed using the HAAS UMC-750 and HAAS Mini Mill. Fusion 360 was employed for seamless integration of Computer-Aided Design and Computer-Aided Manufacturing (CAD/CAM) processes.
Business and Project Management
Makerspace Wiki
Established a comprehensive wiki designed to serve as an indispensable resource for both students and faculty, providing in-depth insights into the technical intricacies of the equipment and Makerspace. The initiative aimed at proactively educating individuals before engaging with any potentially hazardous machinery. Rooted in a commitment to continual improvement, the project seamlessly integrated both physical and online platforms, with the core content housed within the makerspace and accessible online for widespread dissemination. Each section within the wiki meticulously outlines the background, safety protocols, and practical usage guidelines for specific equipment and processes, fostering a culture of informed and responsible engagement.
Makerspace Employee Management
Over my time in the Gannon Makerspace, my role evolved into a managerial position in order to support the faulty and staff working in the space. This involved creating the processes for managing student hours, open lab hours, internal and external projects in the space, optimization through Six Sigma and Agile mentalities, and creating and updating the Makerspace Wiki.
Architecture and Construction
Floor Layout
Played a pivotal role in collaborating with the Architect and Floor Engineer to meticulously plan the layout of furniture and equipment. This involved not only determining optimal placements but also securing essential resources such as power and air requirements, strategically mapping out their drop locations. Subsequently, led the hands-on assembly of the equipment alongside a proficient team, ensuring seamless integration and functionality in the designated spaces.
Air and Power Standoff
In order to get proper clearance of our air and power reels, it was necessary to design and fabricate “standoffs to securely mount to the celling to provide space for these reels to operate. This project involved the design, planning, testing, cutting, welding, and painting of 17 air and power reels for the 6th floor Makerspace at Gannon University.
Balusters
This project was assigned by Tom Hagen to authentically recreate century-old woodworking pieces integral to the restoration of a historic mansion on 6th street in Downtown Erie. Leveraging cutting-edge technology, employed 3D scanning techniques to meticulously capture and replicate the intricate details of the original models. The ensuing process involved precision 3D printing, meticulous sanding, and expert mounting, culminating in flawlessly restored pieces that seamlessly integrated with the mansion’s rich heritage.
Awards
Covid Response Team
Responding to the request of Dr. Keith Taylor, then President of Gannon University, initiated the creation of commemorative coins to honor the dedicated members of the response team during the challenging times of the Covid Pandemic. Crafted with precision, these coins were cast in Pewter, tempered, and blackened. A total of approximately 75 coins were produced, serving as tangible tokens of appreciation and recognition for the invaluable contributions made by the individuals who played a vital role in Gannon University’s response to the pandemic.
Liberal Core Revision
In response to a request from Dr. Walter Iwanenko, Vice President and Provost of Gannon University, spearheaded the creation of commemorative coins recognizing contributors to the 2022 Liberal Studies Core Revision. Similar to the coins crafted for the Covid Response Team, these tokens were cast in Pewter, meticulously tempered, with an innovative consideration of electroplating. Approximately 50 of these coins were meticulously produced, serving as distinguished tokens of appreciation for individuals instrumental in shaping the educational landscape of Gannon University through the Liberal Studies Core Revision.
Building Systems Incorporated
Contributed to the creation of a distinctive award, forming part of a larger ensemble displayed in Gannon University’s Makerspace woodshop. Opted for the utilization of a powder jet printer to 3D print these awards, prioritizing the ability to achieve full-color prints despite the inherent fragility of the process. The decision reflected a strategic choice to balance aesthetics and technology, ensuring the award’s visual impact within the Makerspace setting.
Reverse Engineering and Reconstruction
Jeep Grill
Undertook the redesign and 3D printing of an air conditioner grill for a custom-built 1998 Jeep Wrangler, addressing the challenge of sourcing a suitable replacement. The broken component, evident on the left-hand side, prompted a meticulous redesign. The resulting part, showcased on the right, featured intricately designed fingers strategically crafted to snugly seat into the vehicle, ensuring both functionality and a seamless aesthetic integration. This bespoke solution exemplifies the versatility and precision achievable through 3D printing technology in addressing unique automotive challenges.
NIMBUS
Contributed significantly to the interdisciplinary NIMBUS project, a collaborative effort between the Engineering, Biology, and Physics departments at Gannon University. Specifically tasked with designing a remotely operated canister for the custom-built drone, ensuring the sterile deployment and retrieval of petri dishes at altitudes of up to 400 feet. This intricate project harmonized engineering principles with biological and physical sciences to assess environmental conditions. Additionally, collaborated with a fellow engineer to co-author a research paper delving into the engineering intricacies of the custom drone, highlighting its innovative aspects and contributions to scientific exploration.
Gear Shifter Guide
Responded to a request from Stephenson Equipment Inc. (SEI) to recreate a crucial part integral to the alignment of the gear shifter knob. Leveraging SLA type 3D printing, expedited the rapid and precise reproduction of the component. This innovative solution not only averted the need to repurchase the entire assembly but also resulted in significant cost and resource savings for the company. The broken and damaged piece, visible on the left, stands in stark contrast to the redesigned and efficiently 3D-printed part on the right, showcasing the tangible benefits of additive manufacturing in addressing specific industrial challenges.
Additional Personal Projects
While projects done on company time are always an experience. I strive to hone my skills and practice using equipment with personal projects or gifts that I have made just for fun. It’s certainly not be very helpful in manufacturing and fabricating if you don’t understand the limits and expectations of the machine and design software.
