Innovative Project Experience

Automatic Part Number Stamping System

Problem

Industrial Sales and Manufacturing, a local manufacturing company, posed a problem they were experiencing on the manufacturing floor. A large number of their parts needed to be stamped with descriptive part numbering information. However, this process, though aided by a hydraulic press, resulted in inconsistent, inaccurate, and out of spec parts. This was identified as a bottleneck and needed to be fixed immediately.

Scope

Develop a part marking machine to meet customer requirements.
Check part numbers to ensure that the number matches the ERP system.

Customer Requirements

Metal stamps will need to be able to press into steel and leave a 0.010 deep impression (verifiable).
Press needs to be specified according to engineering analysis
Needs to be quick change fixturing and stamps
Load and unload parts using UR Robot with vacuum grippers.

Objectives

Computer Part Number Identification/Verification
Reduction of Laborious Activities
Increased efficiency of part throughput

Project Status

In development. Deadline of May 2025.

3lb Combat Robot

Scope

Design and build a robot in under 3 pounds to maximize destruction of other robots while balancing control, damage, and strategy of a fight.
Follow extensive rule book for strict design constraints.
Effectively work with a team of 3, managing tasks and objectives.

Team Objectives

Vertical spinner (physically the most optimal spinner weapon).
Elevate core components above competitors weapons.
Utilize advanced fabrication technologies to build the robot.

Applied Fabrication Technologies

FDM 3D Polymer Printing
DMLS (direct metal laser sintering) 3D Metal Printing
Waterjet cut carbon fiber, steel, and corrugated polycarbonate

Project Status

Attended the first ever event with a fully functioning robot. Redesigning based on knowledge gained from first fighting experience.

Dynamic Fusion 360 Spinner Collision Simulation

Scope

Design and test a spinner to determine where to optimize the design.

Team Objectives

Maximize Moment of Inertia
Survive its own impact via simulation

Project Status

Completed simulation

DMLS 3D Printed Maker-Coin

Problem

Makers around the world design and produce maker-coins as a type of trading card system amongst makers. With the advanced nature of the Gannon Makerspace's additive manufacturing, we wanted to show off what is possible with our equipment by designing a maker-coin.

Objectives

Design a coin that features Makerspace branding and common themes.
Design the coin in such a way that it takes advantage of the advanced additive equipment within the space.

Applied Fabrication Technologies

Fusion 360 CAD
SLS & DMLS 3D Printing. Designed for the process, this mount takes full advantage of the unique capabilities and restrictions of SLS 3D printing and DMLS 3D printing. This includes the fine details around the perimeter utilizing negative space to frame the University and Makerspace logos. Both the SLS and DMLS printed coins completed successfully, showcasing full detail, and with minimal support (for DMLS) and warping due to thermal expansion/restriction.

AWS Deep Racer - Autonomous Vehicles Class - Final Project

Problem

After a semester of learning about various applications of AI and gaining a practical understanding on how models like neural networks, computer vision, and deep learning, students were tasked to develop the fastest model for the AWS Deep Racer Challenge.

Objectives

Develop a reward function to define how the model is rewarded based on track parameters provided by the simulation environment.
Tune hyper-parameters to fine tune how the model is mathematically trained.
Train model in computer simulation emulating the real-world track.
Test model on the real world track to verify simulation performance.

Lessons Learned

It is extremely difficult to match a simulated environment to the real world, sometimes it is better to "tune" the real world and try to match the simulation. For example, the boundaries of the track in the simulation are perfectly defined without real world lighting and shading, but the real track can have wrinkles and shadows cast on the track. To solve this with limited capabilities in the AWS Deep Racer console, I took extra time to ensure the track would be perfectly flat and the lighting on the track was even and not too harsh as to cause glare.
Training on a more complicated track than the real world prepares the model for abstract situations in the real world that the simulation may never experience. Being able to take numerous turns after one another in a single track loop allowed the model to be adaptable in the real world to uncontrollable variables like the connection between the computer and car.

SLS 3D Printed 360-Camera Tripod Mount

Problem

I wanted to get into 3D-360 photography and videography, however the available cameras on the market were extremely expensive. I ended up purchasing a camera with a broken tripod mount and reduced battery life with the intention of saving some money. This meant I needed a new way to hold the camera.

Objectives

Design a secure way to hold a 360 camera without obstructing the camera view.
Dual functionality with portable battery cell holders.
Securely mount to a traditional 1/4-20 tripod mount.

Applied Fabrication Technologies

Fusion 360 CAD
SLS 3D Printing. Designed for the process, this mount takes full advantage of the unique capabilities and restrictions of SLS 3D printing.

Page updated

Google Sites

Report abuse