Vacuum Cleaners
The Kenmore 22614 for Sears was my main project at Panasonic. As the lead designer on this, I created and maintained the master model. I started most of the parts and refined them with a team. While at Panasonic I also developed parts and sub-assemblies for other vacuums. Also developed packaging, made improvements to other designs as well as performed and managed UL testing.
https://www.kenmore.com/products/kenmore-22614-bagless-canister-vacuum/
Flash Light
There is a lot packed into this small flashlight. There is a custom machined aluminum tube, which is insert-molded and soft buttons over-molded. It is powered by a AA battery with lots of features packed into small PCBs which are connected with custom made contacts. It has multiple watertight sonic welds and molded-in seals. All included there are injection molded parts, sheet metal, high volume machined parts, light pipes, watertight sonic welds, as well as insert and over-molding, that all fits in the palm of your hand.
Medical Products
I have designed products that have gone through the FDA, UL, and CE approval process. So even if you don’t need those certifications I will still strive for safety and durability for any design.
The Neurorehabilitation product has a unique shape that required vast amounts of medical knowledge to come up with, but in the end, it is simply injection molded and snapped together. The Butterfly BVM has some complex parts with molded-in threads, hermetically sealed sonic welds, and a blow molded bellows. And lots of care was taken for the airflow and pressure differentials in the various chambers inside. The Relja products are surgical devices, they have several over-molded parts, including radio-opaque inserts, as well as a custom screwdriver and depth gauge.
https://www.plasticityneurorehab.com/
https://www.reljainnovations.com/
Phone Cases
This phone case has a card holder integrated into it. It also has a soft edge molded onto the case, it's not a separate piece. This project included cases from the iPhone 6 to X for both the regular one and the plus models. I spent extra time on the first one making the model flexible, so the change from the iPhone 8 to X only took a few hours.
Jet Filter
This is a filter for retaining walls to allow the water to drain out from behind the wall while filtering out the dirt. These even work under water to relive pressure behind a sea wall. There are several different sizes and styles for various applications. This included sheet metal work, welding, die-cutting and injection molding designs.
Heavy Industry
I have followed P&ID schematics in AutoCAD and created 3D models of ductwork for aluminum refinery furnaces, and other piping for air, natural gas, and water. Including the creation of as-built drawings from images and datasheets. I’ve also designed guarding and machine designs using extruded aluminum T-Slot and welded steel. Including a conveyor that moved in excess of 30 tons at a time, as well as other things related to aluminum sows, and molten aluminum. Most of the things I’ve done for this have been custom one-of-a-kind designs except for the Belt Washer, which is used for washing the assembly line belt in a spiral freezer from Regal Construction.
Heart Lines
The Owner of Heart Lines designed the 2D shapes for this line of jewelry, I converted her 2D into 3D by adding the bail on the back and curving the whole pendant. I also helped find the source for production and worked with her to adjust the designs to simplify manufacturing, so every part is always high quality.
Comar Ice Maker
This project successfully reduced the price, energy consumption and size while extending the life and improving performance. I analyzed FEA results to refine the twist tray and calculated the tolerance stack-up to ensure production would run smoothly.
Patents
I have been a part of a few patents. Most of the time I try to find the simplest and most conventional way to do something because using tested methods and standards means less post-production improvements. Those trusted methods are usually not patent-able, but there have been a few times where the best way to do something really was brand new!
Certificate
I am certified by Solidworks as a professional mechanical designer, and also certified with surfacing in Solidworks. These certificates show I have an advanced understanding of the software.
Furniture
I've built furniture as a hobby most of my life. This is a sample of some of my favorite ones.