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Understand/Observe - BounceFly

• Identified different types of human energy and different applications for any type of energy to help narrow the scope

Visualize - BounceFly

• Held multiple brainstorming sessions to generate a number of possible avenues for a solution

• Met with team members on periodically to share ideas and build upon each other's thoughts, sketching on table napkins

Evaluate/Refine - BounceFly

• Once a concept was decided the product was modelled in SolidWorks, a story board was created, and a context story was written around BounceFly for the design contest submission.

Design Objective - Helicopter

Design and build a landing array and computer enclosure for an unmanned helicopter.

The assembly must be lightweight and protect the helicopter and computer in the event of a crash.

The components are to be shipped in pieces so they must be easily assembled.

Understand/Observe - Helicopter

• Talked to team leads about design goals

• Took measurements of the helicopter and modeled the helicopter frame in SolidWorks to identify mounting points

Visualize - Helicopter

• Sketched out concepts for frame shape, mounting solution, structural members, and assembly points

• Evaluated different materials

Evaluate/Refine - Helicopter

• Designed and built one prototype for testing

• After viewing prototype deformation during a crash, created a tool to align and bend the frame back into position

Implement - Helicopter

• Updated drawings for manufacturing four additional sets

• Manufactured and assembled parts

• Managed and instructed an intern student to manufacture parts

Design Objective - TimeNExT

Envision future concepts in timekeeping devices in the year 2154.

Examine ways to embody and communicate time on an individual level so that it is both personal and portable.

Understand/Observe - TimeNExT

• Postulated what will change and what won’t change in 150 years

• Reviewed long-term emerging technologies

Visualize - TimeNExT

• Brainstormed ideas starting with general categories and narrowing down solution criteria

• Sketched concepts out on paper

Design Objective - Ball Attach

Redesign a robotic semiconductor assembly system that attaches 352 three-quarter-millimeter spherical lead balls to the surface of a microchip.

The goal is to improve speed, reliability, and automation.

Understand/Observe - Ball Attach

• Learned the existing system design and constraints

• Learned ladder logic to control programmable logic control (PLC) devices

Visualize - Ball Attach

• Sketched possible solution on whiteboards and paper

• Met with engineering mentor to brainstorm solutions

Evaluate/Refine - Ball Attach

• Modeled design in AutoCAD

• Experimented with different ball pickup and drop off sequences for increased reliability

Implement - Ball Attach

• Created part drawings to send out for machining

• Ordered new OEM parts

• Reprogrammed Seiko robot and Omron PLC devices

• Installed, integrated, and tested new system

Design Objective - Wheelchair Back

Design a system to incorporate an Obus Forme backrest into a standard wheelchair frame.

Make use of the Obus Forme posture support in the design.

Understand/Observe - Wheelchair Back

• Met with marketing and engineering leads to gather requirements

• Used previous experience with visiting nursing homes to build context

Evaluate/Refine - Wheelchair Back

• Researched and evaluated alternative component parts

• Constructed and iterated through numerous prototypes

• Presented prototypes in front of marketing and engineering to evaluate for product marketing and cost

• Created three sizing ranges for different sized wheelchairs

Implement - Wheelchair Back

• Created part drawings, build of materials, and assembly processes, and delivered design specifications to engineering and manufacturing

Design Objective - Thermal Acoustic

A customer has raised an issue about the noise of a Nortel system in their unique application. Find a solution to make the system quieter.

Understand/Observe - Thermal Acoustic

• Reviewed system installation requirements to reproduce environment

• Identified major heat generating processors on the circuit boards

Evaluate/Refine - Thermal Acoustic

• Mounted thermocouples to all major processors on the circuit board to measure surface heat

• Calculated die temperature based on surface temperature

• Mounted thermistor anemometers to the air pathways to measure airflow

• Reduced fan airflow in steps to measure temperature levels

• Placed system inside an anechoic chamber to measure sound levels under different conditions

Design Objective - Battery Enclosure

Create a lightweight enclosure to house stacks of rechargeable batteries for a solar-powered car.

The enclosure must allow for easy installation and removal of battery stacks for competition manipulation and also minimize space and weight.

Understand/Observe - Battery Enclosure

• Met with mechanical team leads to discuss constraints

• Measured solar car cavity and battery stack sizes

Visualize - Battery Enclosure

• Sketched out numerous concepts on paper and modeled the design in SolidWorks