The Problem: The existing porch pillars were outdated and didn’t fit the new modern renovations.

The Solution: I created a drawing of the house and front door. I then sectioned geometry from the door into slices the width of the supports. After choosing a layout I drew a part drawing for each piece. Then I cut out each piece and had them welded in place.

The Value: By using the visual cues from the front door the modern design remains constant across the whole house.

The Problem: A boring commute to work in the summers, and a lack of hands on experience with two-stroke combustion engines.

The Solution: I picked out an old bike on craigslist and a kit on eBay. After fitting the kit to the bike I realized some modifications I wanted to make. The existing motor mount was weak and had little clearance. Plus the chain tensioner was a common fail point. I designed upgrades to both of these and had them welded in place. I rebuilt the bike, the wheels, and greased everything. Then I bought some new parts, and repainted the whole thing.

The Value: I now looked forward to my work commute. By completely taking apart and rebuilding both the bicycle and engine components I gained a deeper understanding of those systems.

The Problem: The handle that was sold to customers was expensive and uncomfortable.

The Solution: I designed a replacement handle that was more comfortable and cheaper. After working through several prototype revisions, both virtual and physical, we ended up on a finale version. I then designed a mold of the part with help from an aluminum casting company. After the design I worked together with the in house machinists to produce the mold of the new handles.

The Value: The new handle is more comfortable than the existing one. By keeping the prototyping, and most of the manufacturing in house the new handle is 75% cheaper than the old one. With this project I also implemented new software and manufacturing capabilities to the company, increasing productivity across many more projects to come.

The Problem: The machine had exposed moving parts and the customer's facility required these be covered.

The Solution: I developed a cost effective safety cover out of sheet metal. This cover bolts onto the existing machine requiring only a few additional holes.

The Value: The customer was able to use the machine safely in the shop. After development this cover became an option for all future machines.

The Problem: The customer was hand-mixing packets of epoxy. This process was time consuming and causing physical strain.

The Solution: I developed a machine that automated this process. Using a reciprocating motion and spring tensioned rollers two packets of epoxy could be mixed automatically. Using different spring forces and mix times helped determine the calculations and testing necessary to ensure the proper mix.

The Value: The Packet Mixer removed the worker from the mix process, allowing for other production. Plus they don’t have to do it by hand.

The Problem: A dozen different product manuals combined with another dozen options resulted in congested documentation. Customers were presented with information that was not was not relevant to their specific equipment. In addition, options that were shared across machines must be updated for each manual creating a tedious task that was prone to mistakes.

The Solution: I developed software allowing for custom documentation specific to each machine. The software allowed the machine type to be selected, the options that were used, as well as the customer’s information, and serial number for their machine. The Manual Maker produced a manual containing all of the entered elements and updated the table of contents accordingly.

The Value: Customer specific technical documentation means everything in their manual is relevant to their machine. When updating documentation included in many machines the information was now in one file instead of 12 copies. Updating now takes less time with fewer opportunities for mistakes.

The Problem: A customer required heavy dispensing equipment to move over a large area.

The Solution: I designed movable arm and pivot linkages. This allowed to equipment to raise and lower effortlessly. The arm also pivoted in two locations giving a sizable range of motion across a dispensing area.

The Value: The solution provided the customer the means to complete the task required. The simple design was cost effective and required little future maintenance.

The Problem: A bracket was required to hold sensor data in place.

The Solution: A simple problem requires a simple solution. After working with the assembly team to create a quick sketch I produced an official drawing. The drawing went through one more revision phase before the final drawing was passed to the production team.

The Value: The finished part was produced from a quick sketch to revision to final drawing in less than an hour.

The Problem: During my bathroom renovation I wanted to add some personality and color.

The Solution: In the center section of the shower I traced the Rebel insignia from Star Wars. Then with a hammer I broke apart a red tile and starting randomly placing pieces in my outline. I also created a decorative wood piece of C3-P0 and R2-D2 for the wall. I cut out the shape, routed the edges and added some detail. After some stain I hung it up on the wall.

The Value: My bathroom now let’s users know where exactly I stand between the Empire and the Rebels.