Objective: A thermal simulation of an injection molding process to analyze the effects of implementing heat pipes.

Procedure: Thermal simulation was done in ANSYS for with and without the heat pipes and the results were compared.

Results: Implementing the heat pipes reduced the peak temperatures of the Cavity and Core side mold by 2 degrees Fahrenheit while increasing the cooling rate of the part increased from 4.66 to 4.94 degrees Fahrenheit per second. 

Documentation: The simulation documentation can be found here.

Objective: Perform a structural simulation of their CSP dish design to determine if the structure could carry its own weight. The structure is to be made from galvanized steel tubing which has a yield strength of 470 Megapascals.

Procedure: The structural simulation was performed in ANSYS. To reduce the computational costs, the structure was split, and a Symmetry boundary condition was applied.

Results: The results showed a maximum deflection of 10 millimeters, and a maximum stress of 1.56 Megapascals at the Absorber supports. The maximum stress experienced by the structure is far from the yield strength of galvanized steel. This means that the structure is able to carry a lot more than its own weight.

Documentation: The full simulation documentation can be found here.

Objective: To design a complete water filtration system that could fit inside a twenty-foot shipping container.

Procedure: I used AutoCAD to create the layout for the system and Solidworks to design the individual parts. The system used a new filtration medium and required the design of its housing as well as its support structure.

Results: The support structure uses only 50 by 50 mm mild steel angle bar for ease of fabrication. The filtration components are located to one side of the container while the control systems and air compressor are located at the other side. The system can produce 788.41 liters per minute or 1134.72 liters per day of clean water.

Documentation: The complete design documentation can be found here.

Objective: To developing an application that aims to help Faculty teaching college engineering math subjects in creating, managing, and checking quizzes. These subjects tend to have the highest number of students in Engineering Department. The application aims to do this by integrating a Language Model for generating variations of questions, as well as OpenCV, a Machine Learning model, to help check standardized answer sheets.

Procedure:
- I started with creating the program's architecture. I had to first learn how to integrate a Language Model and OpenCV into a discrete application. I did this using llama.cpp and OpenCV's build libraries, both of which are open source. I created a simple chat bot with llama.cpp, as well as learned to open and analyze images with OpenCV.
- I then designed a program architecture that integrates both llama.cpp's backend and OpenCV's image analysis functions. The architecture was designed with modularity and maintainability in mind. This makes sure if I need to change something in one of the modules, none of the other modules are affected.

Objective:
- To increase the capabilities of my old Nerf blaster.
- To increase the plunger tube volume, implement a pump-action priming system, and increase the rigidity of the blaster itself.
- Keep the modifications of the shell minimal as well as keeping the original profile of the blaster.
- Modifications should also be doable with no specialized tools or materials. 

Procedure:
- The blaster and modifications were modeled in Solidworks.
- The new plunger tube is to be made from 2.25-inch PVC pipe, and the majority of the reinforcements are 3D printed.
- Springs from a design chart here, this should give a performance of 200-250 feet per second using half-length foam darts (based on similar designs)

Results:
- The new plunger tube volume was increased from 44 cubic centimeters to 126 cubic centimeters.
- The 3D printed parts for the overhaul were design to accommodate metric and imperial hardware, as well as minimize the amount of support material needed, mitigating wastage, print-time, and post-processing time.
- All and any through holes are positioned and sized to avoid intersecting with a layer line on its edges (for 0.4mm nozzles).
- All the parts are dimensioned and sized to mitigate tolerance errors after printing.

Documentation: The full technical documentation can be found here.

Objective: To reverse engineer and reproduce technical drawings of a compound gear.

Procedure: Dimensions and rough sketches were used as reference to remodel the compound gear in SolidWorks.

Results: Compound gear was successfully remodeled and detailed technical drawings provided to the client.

Objective:
- To design a custom hanging shelf solution.
- Shelf must carry up to 200 lb of liquor at the bottom shelves.
- Solution must carry up to 200 lb flat screen TVs on a wrap-around mounting panel.
- The hanging shelf mounts to joist in the roof structure.
- Solution must adhere to building codes.

Procedure:
- An assembly was modeled in SolidWorks using sketches provided by the client.
- Off the shelf (OTS) cast metal parts that adhere to multiple building codes were used for the structure to avoid the cost of custom machining parts.
- A load study was conducted on the bottom shelf.
- An adjustable railing system was designed.

Results:
- Structure uses 1-1/2-inch IPS tubing rated for railings and scaffolding that adhere to the 2024 IBC (International Building Code).
- 1-1/2-inch connecting fixtures used in the design adhere to multiple international building codes.
- Load safety factors of 5 or greater was achieved from the design.
- A fully-adjustable mounting rail system allows for mounting to ceiling joists at multiple orientations and heights.

Documentation: The design study can be found here.

Objective: To design and fabricate a desk arm to hold a microphone using materials and hardware I had present.

Procedure:
- Assembly was designed and modeled in SolidWorks.
- Structure was designed with the use of 20mm and 40mm PVC in mind.
- Designing and Modeling duration: 2 hrs.
- Documentation duration: 2 hrs.
- Fabrication: 7 hrs.

Results:
- Some fasteners were replaced with alternative hardware I had present.
- Desk clamping is temporarily facilitated with hose clamps.
- Bends are not exact to drawings.
- Further development for a better table clamping solution and attachments to secure other devices needed.

Documentation: The technical drawings can be found here.

Objective: To design a walking cane that can also be used as an aid for standing up from low chairs.

Targets:
- Adjustable from 30 to 36 inches.
- Capable of supporting up to 300lb.
- Lightweight and ergonomic.
- Conforms to ISO and WHO requirements.

Procedure:
- Performed material selection to determine the most economical but strong material.
- Designed an initial concept and preliminary structural and stability analysis using mathematical models.
- Refined the design using and improved stress model that shows the stress experienced by individual components as the cane changes orientation and shape.

Results:
- Load rating: 300lb (Safety Factor of 3)
- Cane Materials: 2024-T3/T4, TPR, & Acetal
- Cane weight: 1.24lb
- Adjustability: 30 – 38 inches
- Lowest Height: 15 inches
- Provided a complete BOM, technical drawings, and full assembly documentation to the client