Johnson & Johnson/Ortho Clinical Diagnostics: Redesigned both moving and static parts for a complex blood analyzer. Moved design from low-volume processes to die-cast parts, resulting in greater accuracy and quality, while reducing mass and cost. ROI for the design and tooling was less than 12 months. Earlier projects included design of a mechanism to aspirate and deposit microliter volumes of fluid using a piezoelectric device.
Electronic Brailler, LLC: Created a device that helps blind children learn to take notes in Braille. Designed the enclosure, spill-proof keypad, and printed circuit board features, and was responsible for the top-level assembly.
Luminescent Systems, Inc.: Designed two electronics enclosures for controller boards and the network interface for solid-state aircraft lighting control for a current-production fighter aircraft. Devised a hybrid manufacturing process involving machining and dip brazing while meeting rigorous goals for stress and thermal loading, weight, and cost. Collaborated with working groups across multiple locations and organizations.
Sun Microsystems: Designed a desktop drive array and a 1U rack-mount node for network servers. Challenges included tight space restrictions, air flow/heat management, EMI/RFI, and safety during hot-swap of components.
Reichert Instruments: Revamped an early industrial design model of a hand-held tonometer and its charging base into manufacturable parts. The final product included a multi-shot overmold, and assembly without fasteners.
Guidant Corp: Design for gas-assist injection molding of a pacemaker programmer/recorder/monitor enclosure.
Connected Energy: Housing design for an early IoT device, a rail-mounted motor controller.
NexPress: Design of overmolded motor-brush housings and toner bottle brackets using glass-filled PC/ABS.
Bausch and Lomb: Contact lens packaging, optimization for liquid volume, stacking/nesting, and handling during sealing.
Hill-Rom: Design of enclosure and internal parts for bedside patient interface assembly.
Xerox: Design work on photocopier structure and components - highly successful use of reference datums.
Visron Design: Design of a two-piece self-fixturing enclosure for a card-scan point of sale device.
Char Broil: Design of the deck and top surface surrounding an unusual electric barbecue grill.
Welch Allyn: Otoscope Tip dispenser, Specula models for high-volume production tools
Intel: Design work on an early (2001) effort to invent tablet computing.
Pathlight: Developed latching hardware and faceplates for 1U rack mount trays.
Perkin-Elmer: Redesign for injection and structural foam molding of laboratory analyzer enclosure parts.
RAF Tabtronics: Analyzed processes and redesigned manufacturing fixtures for power transformer components.
Large Seattle-Area Hardware/Software firm: Two injection molded internal components for a current gaming console.
Fisher-Price: Infant wash tub and rinse dispenser, potty trainer/step stool.
Lego Systems: Models for production, plus design work on multiple iterations of Duplo-related toys.
NASDAQ Stock Exchange: Design of a linear scissor-mechanism to mount flat panel displays in the video arrays that you see in every overhead picture of the trading floor.