Portfolio-2013

Mechanical Design EngineerMechanical Design Engineer

[email protected](805)750-0486

1 Vicksburg StreetSan Francisco, CA

Selected Works:

Ronin Metal Masters:Ronin Bicycle Works: Hand-Folded Metal Bicycle Frame – The Kickstarter Project

Sueno Design18 Slot Chassis for Mission-Critical Data Center Networking

Makani PowerAirborne Wind Turbine for High Altitude Wind Power Generation

Andy Davies | Mechanical Design Engineer | [email protected] | San Francisco, CA

Selected Works:

Industrial OrigamiEuropean Consumer Cooktop

Tyco Electronics / Kilovac BrandLEV100 Series Contactor


Tyco Electronics / Kilovac BrandCAP30 Ground Fault Interrupt Relay

Ronin Metal MastersProject:Ronin Bicycle Works: Hand-Folded Metal Bicycle Frame The Kickstarter ProjectRole:Partner / Lead EngineerSummary:There is a rising tide of decentralized manufacturing and rapid prototyping becoming rapid production. My partners and I created Ronin Metal Masters (RMM) to bring this trend to the sheet metal industry. We developed a way to create more accurate parts, remove the need for special dies or tooling, enable more complex geometries and broaden the scope of materials that can be used.

RMM created a method but how to let people know about it? The Ronin Bicycle Works project was a successful technology demonstrator, media campaign and made one outstanding bike!


Also featured in:

1. “Print”Parts are cut from sheet metal by a laser, punch or waterjet CNC machine for a high degree of accuracy and versatility

2. FoldThe tubes transition from square to triangle and back to square. The square ends ensure sturdy connections and the triangular section resists torsional and bending loads. The material is only placed where it is needed much like a skeletal bone structure

3. BondThe frames are riveted and bonded with an automotive chassis epoxy. Epoxied joints can be stronger than the base material and since there is no heat treating, the base material remains strong

4. Enjoy

Ronin Metal MastersProject:Ronin Bicycle Works: Hand-Folded Metal Bicycle Frame The Kickstarter ProjectRole:Partner / Lead EngineerSummary (continued):Crowd-funding was a great fit for us to raise funds to develop the design, buy testing equipment and to pay for a full production run of bicycle frames.

Although the sought after amount was not reached, the resulting press and community building was invaluable.

At right is a screen shot from the website that I designed and built for the project and a brief description of the fabrication process.


Ronin Metal MastersProject:Ronin Bicycle Works: Hand-Folded Metal Bicycle Frame The Kickstarter ProjectRole:Partner / Lead EngineerSummary (continued):A great deal of technical prowess went in to making Ronin Bicycle Works into a viable product. I co-wrote a

patent to protect the intellectual property that we developed.

Lifelike product renderings helped convince

a partner to help produce the prototype bicycle frame.

FEA simulations predicted ahead of time, if a 300 pound person stomping on the pedals for a grueling uphill could prove problematic or not.


Sueno DesignProject:18 Slot Chassis for Mission-Critical Data Center NetworkingRole:Owner / Consulting EngineerSummary:A prominent consulting firm was coming up fast on a deadline and needed a skilled manpower boost. SuenoDesign answered that call.

During that short time, I was able to help troubleshoot the existing design, conceptualize a novel cable management latch, ideate on a dual left or right opening hinge mechanism and keep the skeleton 3D CAD model up to date.


Makani PowerProject: Airborne Wind Turbine for High Altitude Wind Power GenerationRole: Structures TeamSummary:The Makani Airborne Wind Turbine is a tethered wing that generates power by flying in large circles where the wind is stronger and more consistent. It eliminates 90% of the material used in conventional wind turbines, and can access winds both at higher altitudes and above deep waters offshore —resources that are currently untapped. Our goal is the utility-scale deployment of airborne turbines in offshore wind farms.

To help achieve that goal, I prototype processes, build support vehicle structures, create testing rigs, and fabricate production equipment.


Industrial OrigamiProject:

European Consumer Cooktop

Role: Lead Engineer

Summary:A leader in European home appliances needed to cut manufacturing costs drastically on a new line of consumer cooktops. They identified eliminating draw quality steel as the largest cost saving target and came to Industrial Origami for help.

I created a unique curvedsheet metal burner box design with minimal deep drawing, enabling the use of standard steel, and still passed all requirements. To train staff in curved structure design, I prepared training materials.


Tyco Electronics / Kilovac BrandProject:

LEV100 Series ContactorRole:

Lead EngineerSummary:A major automotive brand came to Tyco Electronics to develop a quiet, compact and affordable high voltage contactor for their big introduction into the hybrid market.

Through adept use of computer analysis, fully functional rapid prototypes and novel testing techniques, we were able to greatly reduce production cost, noise and time to market. I ushered the LEV100 through its PPAP, designed production / testing jigs and prepared manufacturing documentation.


Tyco Electronics / Kilovac BrandProject: CAP30 Ground Fault Interrupt Relay

Role: Lead Mechanical Engineer

Summary:Arcing in airplane wing fuel tanks can pose some risk in rare cases. To make flying even more safe, an airplane manufacturer held an open contest to add a resettable ground fault interrupt switch to a hermetically sealed three phase relay, all while not affecting the footprint of the current component.

Our team won the $5million contract and the Tyco Electronics Innovation of the Year award in 2008. As mechanical team lead, I coordinated electrical layout, designed the packaging, and contributed to the magnetically latching switch.

Tyco Electronics Innovation of the Year Award 2008


Mechanical Design EngineerMechanical Design Engineer

[email protected](805)750-0486

1 Vicksburg StreetSan Francisco, CA

Documents

Portfolio-2013