High Temperature Superconductor (HTS) Cabling Line Control Panel (2026)

Overview

In this project, conducted with Solid Material Solutions, I led the design and fabrication of the control panel for a High Temperature Superconductor (HTS) cabling line. This design used a central Automation Direct Productivity PLC for machine control and automation. This system governs the speed of four DC gearmotors through a dual rotary encoder feedback loop. I also developed a custom GUI for parameter setting and information display.

Objectives

• Establish a cost effective control system capable of automating a precision manufacturing process.

• Design a simple and user-friendly interface readily usable by operators.

Outcomes

• Identified and implemented a control system using free and accessible software.

• Proved the closed loop functionality of the system and improved operator user experience.

4 Ply HTS Tape Lamination Line Conveyance System (2024-2026)

HTS Fine Wire Drawing Machine (2023)

Overview

In this project, conducted with Solid Material Solutions, I led the development of a fine wire drawing line designed for the fabrication of BSCCO (Bi-2212) superconducting ceramic composite wire. This unit uses a capstan drive drum for drawing and incorporates a dancing-arm automated dual speed tensioning system for pay-off and take-up of wire. I developed all automation for this system including die load data acquisition, lube temperature monitoring, rotary encoder length measurement, and automated wire feed with automatic stop in the event of a wire breakage. The circuitry was based on a hybrid model incorporating an Arduino microcontroller as well as relay logic for automation. I also developed all mechanical components used, including the unique dancing arm tensioners, drawing lubrication, wire cleaning, pay-off and take-up systems. 

Objectives

• Develop a precision drawing line capable of producing long lengths of HTS wire.

• Qualify the line for consistent operation and repeatability.

• Develop an operations procedure for use in guiding future machine operators.

Outcomes

• Established the consistent production of 2000+ m lengths of 0.16 mm HTS fine wire.

• Instructed additional operators for machine use to expand company knowledge.

• Created complete documentation for tracking and line maintenance.

HTS Fine Wire Twisting Machine (2022)

Overview

In this project, conducted at Solid Material Solutions, I was tasked with developing a device capable of twisting BSCCO (Bi-2212) superconducting ceramic composite wire to various fine pitches. 

Objectives

• Develop a prototype production device capabale of twisting HTS fine wire.

• Qualify the device and create a list of best operation practices.

Outcomes

• Enabled the consistent production of 450+ m lengths of 0.16 mm diameter fine wire to a twist pitch of 5 mm.

• Wrote and produced an standard operating procedure and calibration guide for ease of device use.

HTS Coil Winding Machine Modeling (2022)

Overview

In this project, conducted at Solid Material Solutions, I was tasked with Producing a detailed assembly of an existing coil winding machine to be used for maintenance records and for reference for future upgrades. All modeling was completed using SolidWorks Software.

Objectives

• Create a 3D CAD assembly of an existing manufacturing tool.

• Create a bill of materials (BOM) for part replacement.

Outcomes

• Developed a fully functional SolidWorks assembly without pre-existing drawings or documentation.

• Created a BOM including an organized naming convention for all modeled parts for future reference.

Overview

In this project, conducted at Wentworth Institute of Technology, I worked with a team of fellow senior mechanical engineering students to develop our own novel proposed method of renewable energy production. In our design, a neutrally buoyant hydrofoil composed of 3D printed inserts of varying infill density wrapped in an aluminum skin would be propelled by waves to turn two flexible impeller pumps whose motion would move water upwards to a siphoning reservoir serving as a water battery. When the reservoir reached a specific content of water, it would drain through a siphon and into a generator turbine to produce electricity. A scale prototype was constructed and tested using a wave pool of our own design.

Objectives

• Identify a novel implementation of ocean energy production.

• Create a prototype proof of concept with accompanying report to demonstrate feasibility.

• Learn the end-to-end design process used in R&D engineering.

Outcomes

• Created a subscale hydrofoil, pump, and siphon assembly to test the feasibility of the design.

• Established the ability to pump water using a reciprocating hydrofoil.

• Gave a presentation on the findings and successes of the project to peers.

3D Printed Replacement Bottle Tray (2021)

Overview

In this project, conducted at Diamond Diagnostics, I was tasked with reverse engineering an existing electrolyte analyzer bottle tray to be redesigned in SolidWorks for duplication using 3D Printing. The full tray was broken down from one unit into 4 separate sections, each section was then printed, snapped together, and plastic welded into a singular unit for finishing at the company's in-house workshop.

Objectives

• Create a low-cost replacement for an out of production bottle tray.

• Ensure the design was reproducable for other customers.

Outcomes

• Successfully created a rapid solution for a customer at short notice within a one month development period.

• Refined the design to allow for future modifications to each of the four combined tray modules.

Autoloader Prototype Development (2021)

Overview

In this project, conducted with Diamond Diagnostics, I worked to assist in the development of an electrolyte analyzer autoloader system which would automatically load samples into the analyzer. My role in this project involved the development of initial block diagrams of the operating structure of the system as a whole, it also included the use of SolidWorks as a tool to develop prototype components which I then 3D printed using both an FDM and MSLA printer.

Objectives

• Develop a feasible product prototype for eventual production.

• Support a multidisciplinary team in the design process.

Outcomes

• 3D printed all prototype componentry and reduced lead time by running both the company 3D printer and my personal 3D printer simultaneously.

• Developed a preliminary block diagram and overview documentation for presentation to the company finance team.