Motorola security system

Primary responsibility on this family of products was mechanical design of the plastic parts.  The most memorable part of this project was the client’s requirement to have a red LED be visible through green transparent plastic.  Physics start to get in the way there!  However, we worked with GE Plastics and they were able to formulate a pigment that looked green, but was transparent to the wavelength of the red LED we were using.

Antenna Mount

An innovative antenna mounting solution for Trimble Navigation, using advanced thermoplastics to reduce cost and increase reliability.  30% glass filled PPS!  Very impressive material to work with.

Integrated computer/display/GPS/satellite transceiver

The Trimble Navigation Galaxy Sentinel, a GPS system with built in satellite transceiver, single board computer, and LCD display, for maritime applications.  The use of the sheetmetal midplane really simplified construction, and an internal fan helped even out interior temperatures (also decreased the thermal resistance going into the die cast aluminum enclosure).

Radar Detector Mounting Solution

This aluminum sheetmetal mounting radar detector bracket was designed to fit the Lotus Elise and Exige sports cars, without requiring any permanent modifications to the vehicle, while also relocating the interior lamp for improved illumination. It was designed for low volume, high quality manufacturing.  I produced two batches of parts, enough to recover prototyping costs and turn a small profit.

Semi-rigid cable routing design

A project that required precisely routed semi-rigid cables (designed in Pro/Engineer with Pro/Piping) on a circuit board.  Since then, I’ve found the 3D sketch feature of SolidWorks to be much easier to work with, allowing both rigid controls (straight lines, fixed radii) and freeform designs like splines.

Storage shed

When it came time to build a new storage shed, naturally it had to be designed in Pro/Engineer first!

Wishing well

My wife wanted a small wishing well as part of our wedding. Not finding any suitable ones for sale, I set off to build one, after first designing it in Pro/Engineer.

Trade show truck

To show off the capabilities of a GPS/cell phone product from Trimble, we integrated its input/output functions with a radio controlled truck.