My senior design capstone project, we endeavored to create an “instant” 3D printer. This ambitious undertaking provided valuable insights into the challenges inherent in miniaturizing robust mechanical components. The full report detailing our findings and project outcomes can be accessed here: [PDF Link].
I founded Luxury Architectural Inc., a company specializing in photogrammetry and CNC manufacturing. Photogrammetry is a precise digital measuring technique leveraging multi-angled photography and advanced mathematics to create highly accurate CAD drawings of intricate surfaces. This technology was particularly advantageous for projects featuring curved walls with significant radii where determining the center point posed challenges. We excelled in accurately templating free-form and elliptical curves that traditional measurement methods struggled to define, ensuring an exact fit for the final product.
One notable project involved a residence with sweeping semi-elliptical curves on irregular walls. Our task was to template these walls and balconies to facilitate the precise fabrication of a two partially freestanding staircases and a Juliet balcony. The project culminated with CNC manufacturing of freestanding curved staircases with elliptical-helical railing and trim using a multi-axis CNC router, including the curved stair treads and returns, resulting in an impeccable final installation.
These detailed staircase prints and elevation drawings serve as essential guides for shop employees throughout the manufacturing process. This particular project was commissioned by a renowned architect known for their meticulous standards. The prints required meticulous precision, specifically detailing the exact cut of the beading on the newel post.
While characterizing the epoxy samples mentioned earlier, we encountered a challenge when increasing the ratio of plasticizer—the DMA (dynamic mechanical analyzer) machine couldn’t break the samples. Unfortunately, our current DMA had a maximum force limit of 400 newtons. Fortunately, we had access to another DMA, albeit set up with clamps for viscoelastic materials and lacking 3-point-bending tools.
To overcome this, I designed and 3D printed adapters that could integrate with the alternate DMA apparatus. These adapters included a top piece with embedded neodymium magnets, ensuring secure attachment of the tooling without risk of dislodging. Thanks to these custom adapters, we managed to successfully conduct our research within the constraints of our available time.
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In 2018, I had the privilege of spending the summer at Northwestern University’s MRSEC (Materials Research Science and Engineering Center). During this time, my focus was on characterizing fracture toughness in epoxy polymers at cryogenic temperatures, specifically for aerospace applications, involving a major space launch service provider.
One significant challenge I faced was using a dynamic mechanical analyzer to determine the maximum stress epoxy samples could endure before failure. Unfortunately, the samples frequently failed during the cooling phase when gaseous LN2 was introduced into the sample chamber. This was exacerbated by the thinness of the samples, the rapid gas influx, and the shrinkage of the 3-point bending apparatus, which continually compromised the experiments by causing sample instability.
Fortunately, Northwestern’s engineering center offered access to Stratasys FDM 3D printers. After careful consideration, I devised a solution—a U-shaped saddle that could be integrated into the 3-point bending tools to securely hold the samples upright without affecting the experimental integrity. Although seemingly simple, this innovation was a critical and non-trivial resolution to an ongoing experimental challenge.
This project was both challenging and intriguing, involving an architect’s vision for a distinctive railing design that seamlessly blended wood and metal to achieve a contemporary aesthetic. Beginning with a preliminary sketch, I transformed the concept into a detailed 3D model and lifelike photo rendering of the final product. Upon approval, I proceeded to translate the 3D model into a manufacturable design.
To bring the design to life, lengths of half-moon-shaped rails were fabricated at a local molding company. Subsequently, CAM tool-paths were meticulously applied to the ends, defining their signature three-dimensional swoop and loft. The machining process was executed using a 3-axis CNC mill equipped with a ball end mill, ensuring precise execution of the intricate design through full 3-axis interpolation.
