Selected Projects
This page high-lites some of the many successful projects in which I have played key roles.
Ruggedized Handheld Computing Devices:
Psion Inc., Mississauga
Due to fiscal restraints and recent downsizing the client required external resources to support release of their next generation devices. They required expert level skills in plastics design, manufacturing and CAD design.
Details:
- Creation and modification of complex CAD models to incorporate engineering changes and vendor feedback.
- Recommendations for product and process improvements.
- Assessment and qualification of implemented changes.
- Qualification of inspection reports for first run injection molded parts including supporting tolerance analysis.
Services allowed Psion to maintain strict schedules and progress the product to full production intent. Product successfully launched February 2011.
Laparoscopy Surgical Simulation Tools:
Client name withheld due to IP considerations
Client develops preferred surgical simulation systems that are sold to medical schools and facilities around the world. The task was to develop a low cost system affordable to medical students without sacrificing the fidelity of their high end products.
Sole designer responsible for developing new technologies backed by strong Intellectual Property. Exploiting an emerging market niche and extending Brand recognition to a much wider audience was a key marketing target.
Details:
- Assessment of current products and marketing goals.
- Assessment of alternative technologies.
- Detailed cost breakdowns for development hardware and production units.
- Defined materials, finishes and manufacturing processes.
- Detailed breakdown of production tooling and assembly process.
- Cross discipline collaboration with electrical and software activities.
- Utilized a combination of rapid prototyping and conventional machining technologies.
- Ideation resulting in the creation of 3 mainline design alternatives.
- Designed, sourced, assembled, debugged and evaluated several proof of concept variations of the mainline designs.
- Detailed breakdown of production tooling and assembly process.
- Designed, sourced, assembled and debugged several production intent prototype variations.
- Delivered the project within strict time and budget constraints.
This product enhanced the valuation of the company which was subsequently bought out by a larger entity in the simulation market seeking to expand into the medical field. Worldwide distribution of this product is expected in the near future and it is likely to become the dominant product in this emerging market segment.
Non-invasive Cardiac Analysis Device:
Mespere Life Sciences, Waterloo
Client developed a specialized non-invasive cardiac analysis device targeted to intensive care units and operating rooms. The task was to elevate their seed technology to a commercially viable design. The device utilizes near infrared spectroscopy (NIRS) and records information such as central venous blood pressure, venous oxygenation and cardiac output. These are calculated non-invasively in real time. This is a huge improvement over traditional methods which involve catheterization through a vein into the right atrium of the heart.
Sole designer responsible for development of appropriate technologies and physical designs..
Details:
- Design a prototype device to be used in upcoming clinical trials.
- Produce a production intent design that was cost effective enough to make the product single use and disposable.
- Investigation and selection of medical grade components and materials.
- Investigation and selection medical grade adhesives suitable for adhesion to the fragile skin of elderly and infant patients.
- Investigation and selection of hydrophobic membranes and venting materials.
- Investigation and selection of die cut foams and tapes.
- Investigation and selection of non-evaporating fluids.
- Procure material samples and custom prototype components.
- Production of RFQ’s, vendor selection and liaison.
A functional device was delivered in time for use in pre-scheduled clinical trials. A viable production intent design was achieved and will be implemented on successful completion of clinical trials and appropriate certifications.
Medical Laboratory Automated Slide Preparation Machine:
Beckman-Coulter Inc., Miami
Client required a redesign of their product line due to industry demands for increased lab efficiencies. Heavy internal workloads made it necessary to enlist external design resources.
Details:
- Design of enclosure for next generation laboratory automated blood smear slide preparation machine including integration to the following:.
- Feed/eject systems.
- Sample transport and manipulation.
- Slide staining dying.
- Slide bar-coding.
- Counterbalanced access.
- Multiple access safety interlocks, hazard identification and resolution.
- Structural foam, complex injection molded, machined and sheet metal parts.
- Emphasis on preserving the aesthetic and functional integrity of product line.
- Full documentation including drawings, transcripts, minutes, supporting materials and data.
- Daily investigation, co-ordination and implementation of extensive client driven changes and evolving requirements thru maturity.
- Remote managed: live internet GoTo Meetings featuring real time discussions and screen sharing enabling effective communication between multiple remote design and management parties.
Simultaneous development and integration of internal components and enclosure enabled the client to release the new product for production in an accelerated timeframe.
Next-generation Systems for Xerox Photocopiers:
Xerox IODU, Etobicoke
Client needed to develop faster, more feature rich machines to maintain their market superiority in the face of aggressive competition. The task was to increase operating speeds from 60 to 120 pages per minute while adding functionalities such as stapling, hole punching, booklet making, and increased collating and stacking capacity.
Details:
- Ideation, conceptual and detail design, and documentation of photocopier document feed and finishing assemblies.
- Leading edge utilization of modelling software.
- Design and modeling of complex injection molded parts, mechanisms, sheet metal and cast components.
- Design of electronics packaging, wire routing strategies and cooling solutions.
- Design proof of concept rigs.
- Design iteration and refinement of concurrent build configurations on path to production intent.
- Support with respect to field spares and documentation.
- Design of paper transport systems and related drives, buffering systems, development of compiling technology, stapling systems, tamping systems, jam clearance and latching systems, set management systems and structural systems.
- Worked with developers to resolve functional issues revealed by extensive testing, Taguchi analysis and critical parameter support.
- Extensive tolerance analysis in support of critical parameters.
- Qualification of production tooling.
- Root cause failure analysis and solution development.
The system was launched internationally in 2006 and was quickly adopted by the business community due to its unparalleled efficiency, quality and price point.
Aircraft Maintenance Training and Stationary Flight Simulators:
Atlantis Aerospace Ltd., Brampton
Startup company required design services to develop training simulators from the ground up for military and commercial aircraft. At the time the company had approximately 10 employees.
Details
- Development and implementation of work breakdown structures, hardware costs for program cost analysis.
- Lead designer for simulators of aircraft crew stations and related systems.
- Supervised 2 designers and 4 detailers.
- involved reverse engineering from aircraft drawings to produce high fidelity functional facsimiles of airframes and instrumentation at much lower cost.
- Learning configuration control systems of multiple aerospace vendors.
- Involved replication of crew station structures, flight control and related feedback systems, avionics CRT displays, flight instruments and gauges, seating, control panels and related mechanisms, head up display projection, visual system integration.
- Involved packaging of power supplies, rack mount computer I/O D/O and wiring systems.
- Design of tools, fixtures, molds etc. for manufacturing use.
- Mechanical design with CAD utilizing 3D wireframes and surfacing.
- Cognizant of ANSI requirements, MIL specs, GDT.
- Determination of contractual obligations in regards to documentation and hardware.
- Determination of engineering data required to support design.
- Preparation and presentation of engineering design reviews.
- Research and development of new materials and technologies for manufacturing.
- Manufacturing troubleshooting.
Leading role in successful development of simulators for McDonnell Douglas F15-E, F15-S, CF18, RAF18, Boeing B737, Beechcraft King Air and Lear 35. This allowed the company to grow to over 200 employees over 9 years and establish them as a preferred industry supplier.
Ongoing projects and relationships:
Contract work for several large and mid-sized manufacturers and technology development companies including Psion, Palladium Product Development and Dominion Voting.
Projects include:
- Ideation, design and documentation for voting machine dual sided ballot printing.
- Ideation, design and documentation of several patent pending consumer products.
- Ongoing development of original inventions.