values and processes abstracted; identities removed.
Additively manufactured vibratory conveyor brush that reduces part damage on high-volume lines and can be validated in 5 minutes via an in-house fatigue rig.
Role & Scope: Owned Gen-2 parametric redesign (brush geometry + support structure) through QMS handoff; designed & built in-house vibratory durability rig; authored UTM/UV-Vis/metrology test methods.
#Proof
Capabilities: FAI + SPC gating • Designed & built vibratory durability rig
Business Impact: Deployed by Fortune-500 manufacturers and leading vibratory-conveyor distributors, resulting in $300k+ in first year sales
#Methods & Capability
- Designed & built in-house vibratory durability rig; validation 2 weeks → 5 minutes; transferred to production.
- Authored & standardized test methods for cyclic hysteresis (UTM), tensile/tear (UTM), UV-Vis residue analysis, and design fidelity analysis (hybrid metrology system); methods captured in SOP and trained across operators.
- Design Transfer: SOPs + Documentation for Print, Post-process, Quality inspection, Safety, and QMS handoff.
- Integrated Quality Controls: (GR&R pre-check, FAI on recipe change, go/no-go gates) ensured repeatability and traceability within QMS.
#Process
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Parameter Window
| Parameter Window | Primary Response | Control Window | Failure Signal | First Corrective Action |
|---|---|---|---|---|
| Brush Geometry | Hysteresis Loss | Narrow | Bristle fatigue or high hysteresis loss | Revert baseline taper/profile + requalify |
| Support Structure Geometry | Design Fidelity | Narrow | Distortion, support removal difficulty | Restore baseline taper/profile + requalify |
| Print Energy Density | Tear Strength | Moderate | Increased bristle fatigue and reduced tear strength | Reduce exposure one step within validated window + requalify |
Additional Variables:
- Slice + layer exposure filtering → Design fidelity; Signal: Distortion; Action: Move filter 1 step within validated window from baseline → requalify
- Resin removal → UV-Vis residue; Signal: UV-Vis residue signal rises; Action: extend dwell time 1 step within validated window, or by one cycle → requalify
- Dry-down → Design Fidelity; Signal: part distortion; Action: increase dry dwell 1 step within validated window, safely below Tg → requalify
- Post-cure Energy → Tear strength; Signal: reduced tear strength + increased bristle fatigue; Action: increase post-cure energy 1 step within validated window → requalify