Joseph Flaherty Design Portfolio

ContactEmail:[email protected]:(603)548-6750

linkedin.com/in/joe-flaherty

Design PortfolioJoseph Flaherty

mailto:[email protected]

https://www.linkedin.com/in/joe-flaherty


JosephFlaherty|[email protected]|(603)548-6750

AboutMeHi,I’mJoe.Thanksforlookingthroughmyportfolio.Iliketostaybusyatschoolbyalwayshavingasideprojectgoing.Thisdocumentisacollectionofmyfavoritedesignsandbuilds.

WhenI’mnotworkingorsleeping,Iliketorunandkayak.Ialsolovethrowing;beitabaseball,afootball,orevenajavelin.Latelythough,I’vejustbeenskippingrocks.

Here’smeinanutshell:Ilikemakingthings,throwingthings,and(hopefullysomeday)puttingthingsinspace.MydreamcareerwouldhelplandhumansonMars,andI’vebeenstrivingforyearstomakemyselfqualified.

Ihopeyoufindtheseprojectsinteresting.Icertainlyhadfunworkingonthem.

PastEmployers:KayakinginCapeCod

Me

Athomewithmythreesisters


DesktopGyroscope• Overview• PrecisiononaBudget• AirSystem

RocketInterstage• Overview• Transition• BlastChamber

DesignProjects

Extras• RocketPayloadCanister• RapidEncapsulationDesign• ReverseEngineeringwithNX• RocketLoader&Launcher

Background:• Inspiredbya1940sairdrivendirectionalgyroscope;reusedtheflywheelanditsbearings• Originally,projectwastobeself-funded,sobudgetwasroughly$100Objectives:• Creategyrothatcanbeeasilyspunupwithasmallbikepumporbyhand• Improveairsystemtoallowfullrotationabout2axes(originalhad±80° pitch)• Satisfytheaestheticandsizerequirementsofadesktopornament/toy

Overview– DesktopGyroscope

JosephFlaherty|[email protected]|(603)548-6750OriginalGyrofromWWII CompletedDesktopGyro

ExplodedViewinCAD

PersonalProject– YouTubeVideoFundedbyAmericanInstituteofAeronautics&Astronautics June– August2016

https://youtu.be/Mp-_4qthozQ

PrecisiononaBudget – DesktopGyroscope

CostSavingDesignDecisions:• Optimizedvolumeof3Dprintedpartsbyminimizingwidthandtightly

integratingfastenerholeswithothercavities• Usedjournalbearingsandthrustballbearingstominimizefrictionatlow

cost,thoughsealedballbearingswerepremiumsolutionforairloss• Builtextraroomintojointstocompensateforlargeshafttolerancesand

inaccuratelaser-cutter• Reusedtheoriginalgyro’sflywheelanditscustomballbearings• Gyropurposelynotdesignedtobeheldupsidedown,simplifyingouter

gimbalandassemblyprocess


JosephFlaherty|[email protected]|(603)548-67503DPrintedParts VolumeoptimizedTfitting

ExplodedViewColoredbyFabricationMethod


Hollowshaftconnectselbowjointandflywheel

AirSystemInnovations:• Airdelivereddirectlythroughshaftaxis,allowingforsimpler,

morecompactdesign• StratasysObjetusedto3Dprintinternalairchannels,nozzles,

andpress-fitinterfaceswithdimensionalaccuracy• PVCTubingroutedthroughlaser-cutacrylicframe,reducing

volumeofexpensive3Dprintedparts• AirinletsizedforaSchraderpump,theUSstandardformountain

bikeandcartires

AirSystem– DesktopGyroscope


Fullcross-section;airpathshowninblue



Overview– RocketInterstage

TeamObjective:• BethefirstuniversityrocketryteamtoreachtheKarmanLine(100kmaltitude)MyTask:• Createasmoothtransitionbetweentherocket’stwostagesof4”and6”diameters• Produceanaffordablesystemthatreliablyconnectsandseparatesthestages• SupportambitiousschedulewithplannedlaunchinMay2016DesignChallenges:• Theinterstagemustwithstandlargebendingloadsandheating

• Analysisteambehindschedule;nostructuralorthermaldesigninput

• Rocketisminimumdiameter(sizeofmotorcasing)• Mustinterfacewithmotornozzleandfincanofupperstage

WithAmericanInstituteofAeronautics&AstronauticsMarch– April2016

JosephFlaherty|[email protected]|(603)548-6750ExplodedViewofInterstage– seeanimationonYouTube

Blastchambermatedwith2nd stagemotorcasing

Assembledprototypeincollapsedform

https://youtu.be/6sh16tNumW8

Transition– RocketInterstage

TransitionInnovations:• TheshapeofthetransitionisanequationdrivencurvebasedontheVon

Karmanprofile,whichdescribesaconeoptimizedforsupersonicdrag• Askeletonofcarbonfibertubesbearsin-flightloads,allowingthesmooth

transitiontobe3DprintedinUltem:astrong,temperatureresistantplastic• Theassemblyslidesoverthebottom6”oftheupperstage,providingarigid

couplingthatresistsbending• Blastchambercouldberemovedandrocketcouldstillbestagedbydrag

separation



StructuralCarbonFiberTubes

Blastchamber

VonKarmanprofilebegins

SplinetransitiontoVonKarmanprofile

Notionalconnectionto1st stage

Upperstagenozzle

Mountingringconnectsblastchambertostructuraltube

UltemTransition

2nd StageFinCan

BlastChamber– RocketInterstage

BlastChamberInnovations:• Fastandsimplepre-flightassemblyprocess• Nozzlecapinsulatessecondstagemotorfromseparationblast• Secondsetofshearpinssecurenozzlecapandignitertomotorafterstageseparation• Componentsauto-locatetoensureshearpinholesarealigned• BlastChamberisonlyloadedaxially,socomponentsareplastic



RetainerBreakout(black)mountedtoamockupofthesecondstagemotorretainerring(blue) FullyAssembledBlastChamber

RetainerBreakout

NozzleCap&Igniter

BlastChamberCore

ChargeMountingPlate

TransitionMountingRing

SecondStage

PressureSeal

RocketPayloadCanisterwithAmericanInstituteofAeronautics&AstronauticsforNASAStudentLaunchCompetition2017OngoingsinceAugust2016


Objectives:• Protectfragilepayloadofunknownweightanddimensionsduringrocketflightto1mileapogee• MentorateamofunderclassmenonachallengingtechnicalprojectAccomplishments:• DerivedanalyticalmodeloffoamimpactandwroteaccompanyingMATLABscripttohelp

youngerstudentseasilyoptimizetheirdesign• Returnsfoamyoung’smodulusbasedongeometryandimpactvelocity• Modelishighlyidealized,butprovidesorderofmagnitudeanswerforearlydesigndecisions

• Designedadjustable3Dprintedpayloadcanister• Intricatethreadedpartsareprintedwithoutsupportsandfullyfunctionalrightoffthebuildplate• Foamcushioningisquicklylaser-cuttosizeandgluedinplace

Displacementplotoffoamabsorbingaradialimpact

CanisterWall(rigid)

RocketBody(rigid)

FoamPadding

𝑈" = 𝐸ℎΔ' ( 𝑟*' − 𝑦'� − 𝑟.' − 𝑦'

� − Δ/0𝑑𝑦

"2

3

𝑈4 =𝐸𝐴𝛿'

2𝐿 ;𝑈; =12𝑚𝑣

'

Strainandkineticenergyequationsthatformthebasisoftheanalyticalmodel

Printedcomponentsofpayloadcanister(heightscaleddown,strapsandfoamnotshown)

InitialCanisterConcept

TopCap(locksthreads)

MainCap(compressespayload)

ElasticStraps(forlong,thinpayloads)

LIDARModuleUltrasoundonadjustablepivot

MainBoard

Battery

MicroUSBportWirestohapticfeedbacksystem

RapidEncapsulationDesign

CapstoneGroup’sObjective:• Createacaneforablinduserthat

provideshapticfeedbackwhenobstaclesaresensed

MyTask:• Deliverfunctionalproductassoonas

possible• Releasedfinaldesigninlessthan24hours

• Mountcircuitboards,sensors,andbatteriesinsmall,robustcase

• Designmountforultrasoundsensorwithadjustablepivot

SkillsDemonstrated:• Deliveryofcompactandfunctional

productinashorttimeframewithnoprototypes

• Managementoftolerancesonlow-accuracy3Dprintedpartswithmultipleinterfaces

ForElectricalEngineeringCapstoneGroupApril10-11,2016


EndUserwithCane

ReverseEngineeringwithNX

Note:AllotherprojectsinthisportfolioweredesignedinSOLIDWORKSSelf-TaughtNXSkills:• Reverseengineeredobjectsaroundthehouseto

practicebasicandadvancedtechniquesinNX• Givenlicenseforself-teachingpriortoco-op

• ModelshereweremadewithmerehoursofexperienceinNX

• 7monthsofworkonconfidentialprojectatTytoLifeincreasedskillsfurther

PersonalProjectNXStudentLicenseprovidedbyTytoLifeLLCMay2015


M1riflemodeledandrenderedinNX Realaviators(topleft)modeledandrenderedinNX

RocketLoader&Launcher

Objectives:• Createarobottofind,capture,andloadapayloadintoarocket,thenlaunchit• SimulateaMarssamplereturnmissionAccomplishments:• Leddesign,fabrication,andassemblyasasophomorewithlittleexperience• Cheaplyandaccuratelyfabricatedcomplexassemblieswithlasercutplywood• Integratednumerousindependentlymovingsubsystems• Designedlarge80/20frameusingSOLIDWORKSWeldmentsandgeneratedcutlist

withAmericanInstituteofAeronautics&AstronauticsforNASAStudentLaunchCompetition2015November2014– April2015


Lasercutsnaphooks Telescopingpayloadbaywithsnaphooks FullassemblyinCAD

Telescopingpayloadbayatloadingstation

linkedin.com/in/joe-flaherty

ContactEmail:[email protected]:(603)548-6750

Thanks for ReadingIhopeyouenjoyedlearningaboutmyprojects.Pleasenotethatmuchofmybestworkisconfidential,andeverythingshownhereisaproductofmyfreetime.Whileincomplete,thiscollectionstillcapturesmycontinuingefforttogainexperienceandbecomeabetterengineer.

I’mexcitedtoseewhatprojectsthefuturewillbring.Ifyou’dliketocontactme,pleaseusetheinformationbelow.

Thanksagainforyourtime,

JoeFlaherty


Joseph Flaherty Design Portfolio

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