Part of my recent research required upgrading a 4K projector to be able to utilize 3 wavelengths of near-UV or UV light. This required the addition of a high power, 60W UV LED, lens array, and dichroic mirror to pass the light through to the digital mirror device (DMD). To achieve this, highly precise measurements of existing mounting hardware had to be taken, and custom mounting hardware had to be manufactured. As such, this was my first foray into metal laser cutting for extremely precise metal brackets.

Measurement of every mounting hole and surface had to be precise and correct. This was especially difficult since the original projector could not be taken apart due to ongoing research. Finding machines capable of utilizing high temperature materials was also a concern, as the operating temperature of the high power UV LED could be over boiling, which makes normal printed plastics unusable.

This set of mounting brackets was a good design exercise in replicating existing hardware, but also in modification as a new LED package and lens array were to be housed. Additionally, this project allowed significant practice in interfacing between multiple standards of mounting holes while still allowing access to screws, nuts, cables, and important hardware.

As part of a course on vegan and plant based meats, a capstone project was assigned to create a concept product that would help those looking to eat less red meat to do so easier. The Artemix is the solution that won both the in class competition and the school wide "Collider Cup", a competition for innovative ideas and technologies within all UC Berkeley design classes.

The central challenge to designing and producing the Artemix mockup was the time allocated. The CAD work, printing, and assembly of all parts shown in these images took just 3 days. Assembly was also marred by the fact that 3D printed PETG plastics are extremely hard to bond together with adhesives. In the end, the mockup was held together with nothing but tape and hope.

This project helped me learn how to fully utilize the resources available to oneself. I engaged the help of 2 friends with 3D printers in order to have all of my parts ready by the date of the presentation. After this experience, I have learned to plan my prototyping assembly process before actually beginning it, as none of the household glues I had worked on the printed PETG items.

The most difficult challenge that was faced when designing the T-Pepp phone case was making it compatible with phones on the market. The case needed to interface perfectly with an iPhone, with all its complex curves. It also needed to be compatible with the wireless charging feature that most new iPhones have. Designing to fit these parameters turned out to be the most difficult part of the engineering process.

The main takeaways from this engineering process was the experience gained designing snap fit enclosures and flexible members. Plastics are very useful but to use them to their full potential we take advantage of their material properties. On T-Pepp, I designed plastic snaps that click the camera grip into 90 degree positions. Kicking the grip to one side will also give the snaps enough clearance to remove the grip entirely. Getting these technical components right was difficult but rewarding.

The main challenge with this project was the design of the tower. It needed to be stiff from all directions to reject wind forces. It also needs to be light and hollow. These two criteria made the windmill tower into the symmetrical shape that you see now.

The main takeaway from this project was to do lots of research. A good understanding of static mechanics helped during the design process. Understanding how materials behave during compressive strain was useful since this allowed the design to be exceptionally stiff.

The main challenge for this design was measurement. Measuring each radius and curve, as well as the length of each cylinder was difficult without the proper tools. I used only a ruler to determine the sizes of the handle and fan housing.

The takeaway from this project is to check your measurements twice and print once. I measured the length of the fan housing wrong and so the top of the hair dryer touches the wall when it is not supposed to. What an embarrassing mistake!