Design Portfolio

Jared Smith

2016

Highlights● New product development

● High tolerance machining

● Sheet metal

● Aluminum extrusion

● Cosmetic surfaces

● Rapid prototyping

● Plastic Injection Molding design

● Over-molding

● Production drawings and documentation

● Welding

● Working with suppliers to explore new technologies

● Fixture Design

● Overlay and labeling design

● Cable design / Ultrasonic Welding

● Product support● Investigation of product issues● Manufacturing support

● Cost reduction

● Design challenges

● Personal woodworking projects

New Product DevelopmentTest and Measurement – PXI Modules● Inception to Production● High tolerance machining● Sheet metal● Aluminum extrusion● High voltage/high current● Quoting ● Supplier selection● BOM creation/product life cycle● Overlays● Verification testing● Assembly fixtures● Test fixtures● Work instructions● Production hand-off

New Product DevelopmentSlot Machine Topper● Adjustable monitor stand ● Sheet metal design● Rivets● Painted exterior surfaces ● Ensures proper grounding

New Product DevelopmentAccessory Cables● Cosmetic surfaces● Material selection● Supplier selection● Supplier support with new processes● Shielding● Over-molding● Plastic injection molding● Verification testing● Labeling

New Product Development

Rapid Prototyping● FDM● SLS● RTV silicone mold

New Product Development

Rapid Prototyping● Hot wire cut foam

New Product DevelopmentRapid Prototyping● Target practice Deuling Tree● Solid model● Metal fabrication● Welded● Tested● Start to finish in 12 hours

New Product DevelopmentProduction Drawings● Large assemblies

New TechnologiesUltrasonically Welded Cable shells● Never before used on cable enclosures at National Instruments

● Allowed quick change from over-mold to injection molded plastic

● Conducted research● Developed process working directly with supplier

● Selected tooling● Selected materials● Trained Mechanical Engineering team

Product Support

Game Floor Kiosk Conversion● Conversion from Solidworks to Creo 2.0

● Created over a hundred solid models and production drawings

● Integrated new auto-latching door design

● Welded parts

Product SupportRoot Cause Analysis of Coin Jams● Designed test setup● Created LabVIEW program to count coins and measure time between cycles

● Recreated jams in house● Discovered root cause ● Updated design ● Conducted reliability testing

Product SupportInvestigated Field Issues ● Connector failures● Panel failures● Solder failures

Manufacturing Support

Production hand-off● Developed assembly processes● Created detailed assemby instructions● Developed assemby fixtures● Trained manufacturing team

Manufacturing Support

Fixture Design● Reflow oven fixture● Assembly fixtures● Gluing fixture● Cable solder fixture

Design Challenges

EMI Gasket● Adding gasket to front panel proved to be more difficult than anticipated

● Conducted brainstorming meetings

● When no feasible solution discovered, re-evaluated which constraints could be adjusted

● Longer connectors allowed for enough material in panel to capture EMI gasket

Design Challenges

Connector Block Assembly Bow● Integral part to RF product● Tightened connectors caused deformation ● FEA used to predict behavior of next revision

Cost Reduction

Working with Vendors● Changed to less expensive vendor

● Designed out high cost features

● Material change● Re-used parts on multiple products

● New parts verification

Personal ProjectsPower Generating Exercise Bike Prototype● Alternator to generate electricity while you exercise

● Created LabVIEW VI to measure power output and speed

● Presented results at company tech fair● Created a second revision

Personal ProjectsBookcase from Scratch

Personal ProjectsBeekeeping● Beehive stand with moats to prevent ant invasions● Queen Castle for queen bee production● Custom honey label with beeswax seal on lid, won first place at county competition

Personal ProjectsWoodcarving a spatula by hand● Log● Hatchet● Pocket knife

Personal Projects

Balcony Railing Replacement

Personal ProjectsTeardrop Trailer● Built onto 4' x 8' trailer● Battery plus inverter power supply

● LED lights● Powered fan vent

Personal ProjectsUnderground Tornado Shelter● 53' long● 9.5” tall● 8' wide

Personal ProjectsUnderground Tornado Shelter● Integrated door frame built into concrete floor

● 10'x16' shop built on top● Shelter roof supports 2 feet of wet soil

Personal ProjectsUnderground Tornado Shelter● Custom welded steel door weighs 750 lbs● Concrete filled to provide extra strength

Personal ProjectsUnderground Tornado Shelter● Lift assist provided by two gas springs● Integrated bolt locks

Personal ProjectsUnderground Tornado Shelter● Custom ship ladder with integrated hand rails● Magnetic door lock ● Bottle jack for backup door lift

Personal ProjectsUnderground Tornado Shelter● Small kitchen● Water heater● Shower● Macerating Toilet

Personal ProjectsUnderground Tornado Shelter● Calculated beam stress with additional factor of safety● Posts and beams support 2 feet of wet soil● Design verified by driving a skid steer on top