Past Projects

Designed for patients at risk of skin breakdown due to prolonged moisture exposure, this device removes liquid waste while maintaining skin dryness. Featuring a moisture-wicking layer, suction tube, dissolvable barrier, and foam cushion, it provides up to 12 hours of continuous wear. The system is non-invasive, unisex, and safe for sensitive skin. By reducing infection risks and discomfort, it supports both patient dignity and caregiver ease.

This system simulates thermal management for electric vehicle components, including battery, cabin, and motor. Using an Arduino Mega, H-bridge, touchscreen display, PID controller, and adjustable heat exchanger, the system allows users to model heat distribution under dynamic inputs. TSA-compliant and refrigerant-free, the setup promotes energy efficiency and offers a valuable educational platform for real-time thermal control systems.

This in-line functional tester validates structural performance of shelving units during production. It applies 300 pounds of pneumatic force to a shelf and uses laser sensors to detect deformation beyond specified limits. Featuring a modular design and X-Y gantry movement system, the tester ensures safe operation via dual-hand controls and real-time feedback, helping Madix maintain quality standards while streamlining QA processes.

KONE’s team addressed SKU overproliferation and installation inefficiencies in elevator bracket systems. By harmonizing 18 designs into 3 bracket types and introducing threaded rods for easy adjustability, the team reduced installation times and full chain costs by an estimated 16%. The solution improves manufacturability, simplifies inventory, and supports scalability across KONE’s MonoSpace elevator platforms.

This project revamped a commercial meat smoker plagued by inconsistent internal temperatures. Through six key improvements—new airflow system, fan, gas burner, firebox redesign, insulation updates, and control tuning—the team transformed the unit into a consistent performer. The redesigned smoker now maintains ±7°F across the cook zone, significantly improving product quality and operational efficiency for J&R Manufacturing’s clients.

To prevent airflow obstruction due to frozen moisture in marine vessels, the team designed a PID-controlled electrical heating system. With a heat trace wire frame, thermocouple feedback, and custom setpoint controls, the device ensures consistent temperature regulation. Delivering 900W of heating power, the system supports safe, automated operation and is scalable for broader deployment across CECO’s industrial separator platforms.

This automated platform streamlines assembly of round electrical junction boxes. A conveyor system moves components into position while a gantry-mounted electric screwdriver assembly fastens screws and wings accurately. Designed to minimize labor and improve production consistency, the system enhances throughput while maintaining ergonomic safety standards and adaptability for multiple product configurations.

This fully automated cell assembles 14SO electrical junction boxes by inserting wings and screws with precision and speed. It features an aluminum chassis, linear actuator, pneumatic wing insertion system, vibratory screw feeder, and Dixon screwdrivers—all coordinated via Arduino Mega. The system reduces assembly time from 16 to 8 seconds per box (50% faster) while maintaining user safety through intuitive controls and smart actuation. It replaces repetitive manual tasks with a robust and scalable manufacturing solution.

This semi-automated robotic system organizes fiber optic connectors and contacts for packaging and assembly. Equipped with an xArm5 collaborative robotic arm, SICK camera, and SMC gripper with hall-effect sensor feedback, the system performs pick-and-place tasks with 0.1 mm repeatability. Components are oriented using vibratory feeders and trays, and placed into designated bins for packaging. Features like touchscreen controls, 24/7 lights-out operation, and component modularity increase throughput while minimizing human error and labor.

Amphenol tasked the team with developing a precision fiber alignment tool for polarization-maintaining (PM) optical fibers. The device aligns the slow and fast axes of fiber stress rods within a tight angular tolerance (θ = ±1.5°) using high-resolution positional control (1.45 milliradian). Featuring a two-part fixture system, the solution maintains stability during alignment and applies low-force, controlled pressing to secure the fiber. Successfully achieving extinction ratio readings up to 26.2 dB, the project supports enhanced reliability and performance in AFSI's ruggedized fiber optic product line.