AEROSPACE
Wing and Cockpit Lighting Enclosures
This is one of two enclosures I designed for a current-production fighter aircraft. It holds a power supply, backplane, and several stacked logic PCBs.
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The design met rigorous weight and cost targets and passed all stress and thermal tests.
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The critical fabrication choice was to use dip-brazing to join the five parts of the upper and lower sections, which allowed for minimum wall thicknesses and feature-rich interior surfaces for heat-sinking and efficient packaging. I previously used this technology in the design of a rugged laptop computer enclosure.
The second enclosure contained a much lower heat load, and we were able to minimize packaging weight by attaching the larger masses directly to the walls. We made best use of the dip-brazing technology to come up with a design that was extremely light and strong.
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This project involved teams at locations on three continents - robust file revision control and active communication were critical.
I also have extensive experience with design for aluminum die casting.