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A Really Awesome 2 Part Mold

Making the two part mold out of silicone was the most challenging part--especially when dealing with the complex geometry of a skull.

 Cast in Wax                  

The skull was cast in brown wax, eventually I'm doing a lost wax casting.

I made an Instructable!

To document my process and share with others, I put my project on Instructables. In that time, it was featured on the front page, and was a winner of the Concrete and Casting Contest.

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Butter Forms


Engineering and fabricating

tools for a local bakery.

Butter Forms


Engineering and fabricating

tools for a local bakery.

Fixing an outdated bottleneck process.

Even small businesses face classical manufacturing problems. A local bakery needed to expand production to meet expected demand and needed special tools to decrease time in a bottleneck process. I developed a process which uses food safe silicone molds to replace the process of forming butter by hand. 

Economics inform decision making.      

An analysis of the engineering economics helped the team make a choice on which direction to take the project. Adding another human operator was inefficient, and the silicone molds reduced cycle time from 30 minutes to 2 minutes. The economics showed a break-even point which provided a competitive return on investment for the tooling.

Tooling made, silicone forms in service.

After testing a prototype silicone form, I machined mold negatives out of HDPE on a Shopbot 3 axis router and cast the food safe silicone. After curing, the food safe silicone is ready for service, dishwasher safe, and durable for over several thousand cycles. 

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Home Goods Manufacturer


Capturing 200 years of craftsman knowledge.

Home Goods Manufacturer


Capturing 200 years of craftsman knowledge.

documenting centuries old products

This client had no technical information about the products they had been making for almost 200 years. I helped the corporate team translate the craftsman knowledge into a modern 3D file format.

Setting up for the next century of manufacturing              

After making the 3D models, I produced a set of drawing packages for the products so they could preserve relevant information and modify manufacturing if need be.

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Custom Motorcycle Parts


Engineering and Design for a custom motorcycle shop.

Custom Motorcycle Parts


Engineering and Design for a custom motorcycle shop.

ENGINEERING FOR COMMUNITY OWNED BUSiNIESSES

 

Designing and fabricating custom motorcycle parts for the builders at Madhouse Motors.

 

Click here to learn more.

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Classroom Hives


Classroom Hives


design

Designed updated parts for the Classroom Hives observation hive system. 

prototyping

Prototyped a solution for Classroom Hives to approve. Several changes were made from the original design, but made it cheaper to build.

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manufacturing

Sourced a local manufacturer for the new hive parts. Finding a local shop to work with meant that communication would be faster, easier, and more convenient. We also give back to the community by sourcing locally.

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Wire Rope Isolators


Modernizing Technical Information

Wire Rope Isolators


Modernizing Technical Information

Modernizing information

I helped this client who makes wire rope isolators update their catalog to a more efficient and modern 3D CAD format. 

Photorealistic renderings      

I also produced sets of renderings for each product model to be shown in the catalog. 

special cases and one-offs

Occasionally small adjustments need to be made to fit clients needs, or special models need to be made up for the clients customers. 

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High End Speaker Cabinets


Manufacturing sourcing and

mechanical engineering for 

speaker company

High End Speaker Cabinets


Manufacturing sourcing and

mechanical engineering for 

speaker company

Updating hand drawn documents

All the client had to start were outdated hand drawn documents. Needing to source from a new manufacturer meant I needed to update their design and put it in a modern file format. 

sourcing for local manufacturing  

This client needed the product fast, so I helped them track down a local shop that could cut all of the pieces for their cabinets. 

Modern Manufacturing

I gave the go-ahead to a local cnc routing shop and the parts were made on time and under budget. 

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Raspberry Pi Case


A thoughtful crust!

Raspberry Pi Case


A thoughtful crust!

Designed for My Fellow Students

When BU Students started getting Raspberry Pi's en masse for class, they needed a mechanical engineering student to help them protect their Pi's!

 

Click to Read More....

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Disk Brake Redesign


Disk Brake Redesign


Mechanical Engineering Senior Design Project

For my team's mechanical engineering senior design project, we were tasked with improving the efficiency of tension control disk brakes.

 

Click here to read more!

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Beekeeping


Beekeeping


4 Years of Beekeeping Experience. From University Clubs, to the Backyards of Suburban Boston.

Home Apiary

I keep what I like to call a teaching apiary at my home. Its where I learn more about bees, and can teach my family and friends about bees. Our home apiary has been used in several Boston Area beekeeping events!

In Home Observation Hive

I keep an observation hive at home. Cohabiting with the bees and observing their movements on the day-to-day brings no end of wonder and fun.

I made an Instructable!

Click on the Instructable robot to see my award-winning Instructable about how to install a hive of bees in your backyard and get bee kisses from the pollinators themselves.

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3D Tic Tac Toe


A Battle of wits in three spatial dimensions!

3D Tic Tac Toe


A Battle of wits in three spatial dimensions!

My Intro to Design and Manufacturing

My team decided to build a 3D Tic-Tac-Toe game board and pieces for our introductory design and manufacturing course.