Prototype support framework and modular enclosures for a high-frequency imaging system.
Designed and fabricated for the Center For Metamaterials And Integrated Plasmonics at Duke University under a subcontract issued by Duke University under Duke University’s contract HSHQDC-12-C-00049 with the Department of Homeland Security Science and Technology Directorate. Framework and enclosures fabricated from aluminum extrusions, custom machined aluminum, fiberglass sheet, and SLA parts. Approximate framework dimensions 82” x 82” x 18”, approximate enclosure dimensions, 24.5” x 18.5” x 4.5”.

Anti-tamper mechanism for an RFID tag.
A mechanism was designed and fabricated to detect removal of an RFID tag from a mounting surface, and in the event of a removal attempt to permanently destroy the electronics inside the tag. The mechanism is inherently resistant to mechanical shock and impact in order to prevent false triggering. The project included design and fabrication of a weatherproof and impact-resistant tag housing. Developed for Dirac Solutions, Inc. and Lawrence Livermore National Laboratory. This device is currently patent pending.

Automated testing fixture for use with surgical laparoscopic tools.
A fixture was designed and fabricated to hold one of several different surgical laparoscopic tools and to test the tool's cutting force and output the measured force and a pass/fail indication. The fixture included a complex roller clutch and cam mechanism to feed and tension a strip of elastic material used for the actual cut testing. The fixture also included a microcontroller, stepper motors, a force sensor, and numerous limit switches. I/O was provided with buttons, selector switches, LEDs, and a force displaying digital meter. The fixture also included safety interlocks preventing any component motion while the lid was open. All electronic integration, including design of the force signal amplifying and conditioning circuitry, was performed by Design Innovation. (Control electronics not shown.) Developed for ConMed.

Light-up Rudolph Nose for a Boeing 747.
The Evergreen Aviation & Space Museum in McMinnville, Oregon commissioned this ornament for the decommissioned Boeing 747 that is displayed on their roof. It is used as part of their annual Winter holiday celebration, and is attached to the nose cone with a set of custom straps. It is made primarily of aluminum and polycarbonate. To the best of our knowledge, it is the largest light-up Rudolph nose in the world.

Test fixtures for electronic products.
Electronic test fixtures are designed to meet specific needs, incorporating features for precision locating and holding of assembled curcuit boards. Spring-loaded, conductive pogo pins are generally used to make electrical contact with points requiring power and signal I/O on the circuit board. Fixture interfaces can include connectors, switches, indicators, power supplies, and signal conditioning circuitry. Fixtures are generally machined from Delrin plates for durable, precise feature location and electrical insulation. Mechanism parts are made from metal or plastic as needed, and electronics enclosures and/or base stands are generally made from commercially available aluminum or steel enclosures. If needed, toggle clamps, precision steel guide rails and linear bearings are used.

The test fixture shown holds an assembled pc board to be tested in the black Delrin nest, and the lid is clamped down and latched to hold the board in place. Torsion springs on either side of the lid hold it in the raised position when not latched. The middle portion of the fixture holds a plate loaded with the various pogo pins, and slides along the vertical rails on linear bearings. This pogo plate is driven up and down by linkages and the toggle clamp shown at the left. Connectors on a circuit board under the pogo plate provide input and output.