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Four-speed clutchless EV transmission
Wrightspeed, Inc.

I initiated and developed the major conceptual redesign of the gearbox within tight space constraints, including linear pneumatic shifting system with improved actuators and speed/position sensors.

Source: https://www.fleetowner.com/running-green/article/21164594/stealthy-wrightspeed-ready-to-make-noise-in-refuse

Wiring Harness Layout for Thermal Management System

Shown is the board I created with the layout of a wiring harness that we made at Wrightspeed to convert the powertrain of an existing bus.

The board enabled my EE teammate and me to lay out the wires with the correct length and identify required splices and locations of branches. We then successfully installed the harness in the bus.

This harness connects the main thermal control board to all the thermal systems such as the battery thermal management system (BTMS), HVAC compressors, radiator reservoir water level sensor, and radiator outlet water temperature sensor. The BTMS pumps oil through the batteries and then an oil to refrigerant heat exchanger.

Custom desk with shelf for monitors and speakers

I designed and built my desk using custom aluminum extrusions, laser cut Baltic Birch plywood, 3D printed drawer sliders, and hand finishing.

Click "Details" button for more information.

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Filament extruder with closed-loop controls and integrated winder

I designed and built a machine that extrudes plastic filament for 3D printers from resin pellets. I completed and tested the extruder as an independent senior project at USC.

Since then, I have designed and fabricated an integrated winder, and improved electronics packaging with custom PCBs, wiring harness and enclosure panels. I am currently in the process of adding a Hall sensor tachometer and programming the Arduino.

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iPhone & Apple Watch charging stand

I designed and 3D printed this personal project with these design features:

charges iPhone and Apple watch simultaneously
fits a variety of iPhone models and cases via interchangeable cradle pieces
stable and non-slip
manages cords
elegant in design and appearance
easy to 3D print, including for Thingiverse users, requiring minimal support material and post print processing
easy to assemble via snap-fit (no screws or adhesives)

Telescoping mast for antennas

For Land Systems Corp., I designed, fabricated, installed and met product requirements for a 14-ft. telescoping mast for antennas that controlled unmanned electric vehicles for agricultural spraying and track inspection.

Optimized design in SolidWorks for fabrication via CNC five-axis machining, waterjet cutting and welding.

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Testing and analysis of high capacity thrust rig

For Honeywell Turbo Technologies, I increased the accuracy of the test rig for thrust bearings that support high axial loads on the rotating shafts of turbochargers, using systematic testing and analysis.

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Custom ventilated enclosure for 3D printer

I designed a fire retardant ventilated enclosure for my 3D printer using SolidWorks Sheet Metal for fabrication via waterjet and bending brake.

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Motorized recliner chair

I designed and built two versions of a motorized recliner chair:

Electric: 900 W motor, 12 V batteries, motor controller, welded chassis. Reached 15 mph.

Engine: 9 hp motorcycle engine, electro-pneumatic shifting, wiring harness. Achieved 40 mph and 150-ft. wheelies.

Details

It was featured in Popular Science: http://www.popsci.com/cars/article/2011-04/college-student-roars-around-campus-motorized-easy-chair

and (left) "Daily Planet," Discovery Channel Canada: ·

https://youtu.be/419AQ1KdhFg

"Useless" Box

This is a "useless" box that I designed in CAD and 3D printed.

It uses a servo motor modified for continuous rotation, and a DPDT switch and limit switch.

Throwing the exterior switch activates an arm that comes out of the box and flips the switch back, thereby reversing motor direction. The retracting arm hits an interior limit switch that cuts motor power until the user throws the exterior switch again.