SUFFOLK STUDIO
Handmade wooden wares from sustainably sourced local lumber.
All sorts of goodies to scoop with, eat out of, and decorate with!
Handmade wooden wares from sustainably sourced local lumber.
All sorts of goodies to scoop with, eat out of, and decorate with!
Welcome to my professional portfolio! Here you’ll find examples of my most impactful professional projects and accomplishments. Unfortunately some of my most interesting projects are confidential and cannot be listed here.
If you'd like to see my personal portfolio, please click here!
American Robotics | 2022
Drone production increased from 1 unit per week to 10 units per week. Quality also increased, as tracked by interdepartmental inspection. No drones were delivered to the testing team behind schedule.
Upon taking over production of these autonomous drones, I audited the Bill of Materials, redesigned the production line, and created detailed work instructions and inspection plans. I also trained technicians to assemble & test, and automated much of the inspection process.
American Robotics | 2022
This testing chamber was used to perform at-speed testing of individual drone components during production, as well as housing a fully assembled drone for power testing. This chamber was in SolidWorks and can accommodate a variety of test setups, sensors, and power inputs.
This testing chamber considerably increased the safety of testing a unit with multiple propellers. Additionally, acoustic insulation was installed to allow an operator to be at this station without hearing protection. Finally, the unit is much more ergonomic and user-friendly than previous iteration.
ePropelled | 2022
Compared to previous testing methods, setup time was reduced by 40% and number of compatible SKUs increased by 36%. Cycle time was also reduced by approximately 25% and overall reliability increased, allowing for higher throughput.
This dynamometer performs final factory acceptance testing on a full range of electric motors. It is designed to be fully modular and compatible with all 11 current SKUs and any future designs. The unit rotates at up to 10,000rpm and completes a test in under 60 seconds.
ePropelled | 2021
Working closely with the power electronics team, I designed all the mechanical components for this Intelligent Power System. All components were designed in Solidworks, and this product entered production in early 2021. Design, prototyping, and qualification took approximately 1 year; with early revisions weighing nearly 50% more and being considerably more expensive to produce.
Hutchinson Aerospace & Industry | 2019
I saw a need for improved rapid prototyping abilities and designed this space for use by all engineers. Both manufacturing and design engineers needed better capabilities for prototyping production solutions as well as customer products. Small, simple, accessible 3D printers, as well as a cleaning and finishing tools provided that opportunity for increased productivity.
Making paint and adhesive masking fixtures, both 3D printers paid for themselves and generated over $5,000 in savings within their first year of operation. This area has also cut lead times for design prototypes by up to 300%.
Hutchinson Aerospace & Industry | 2019
Implementation of this system completely eliminated operator injuries during this operation. Additionally, it doubled throughput, with additional opportunities for future improvement using automated loading. Parts rejected due to operator error also decreased by 70%, and the customer noted improved overall finish consistency.
I designed and programmed this robotically-assisted trimming system primarily to improve operator safety. Skilled operators were hand-trimming molding flash and experiencing injuries due to the repetitive motion. This Universal Robots UR3 Cobot was able to trim and buff both sides of the component, allowing the operator to focus on loading, unloading, and inspection.
Hutchinson Aerospace & Industry | 2018
Implementation of this fixture eliminated manufacturing defects during this operation. Moving from the more established manual hold-down systems to a pneumatic system decreased worker fatigue and allowed for a hands-free operation, improving safety.
I designed this fixture to remedy shifting components during a forming operation. After studying similar existing manual fixtures, I designed a pneumatic system to hold the parts down automatically. Modeled in PTC Creo, this was the first production fixture to be made from a combination of both machined and 3D-printed parts.
Hutchinson Aerospace & Industry | 2017
PTC Creo Rendering
Using PTC Creo, I designed this fixture to move a production part from hand assembly to automated pneumatic assembly. This tooling allows the operator to insert both components and cycle the machine while keeping their hands at a safe distance.
Moving from hand-operated arbor press assembly to pneumatic press assembly increased production time by 30%. This tooling also increased assembly accuracy to 100% with the use of mechanical stops.
Hutchinson Aerospace & Industry | 2017
Product in white and blue, assembly fixture in dark grey
This fixture allowed a single operator to lay up all components and install hardware in less than 10 minutes; consistently resulting in compliant parts. Before implementation of the fixture, assembly required two operators and approximately 30 minutes.
I designed this fixture to aid assembly of a heavy product consisting of multiple machined and rubber molded components. I used PTC Creo to model it and a Flow waterjet to cut all necessary components in-house.
GARY PIVOVAROV | 2022
