https://www.thoughtbombdesign.com/home daily 1.0 2026-06-27 https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782422725285-TYQXIT3NGTDC0JWDKXH2/20170110_124915.jpg Home On this robot head project I got to package a lot of electronics and sensors as well as design the eyelid and head tilt mechanisms. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782433201068-DS90Y3XNNJ83IMAI2XSR/0509181936.jpg Home Designed custom overmolded silicone and urethane parts, 3d printed and machined the molds, and cast the parts. Used vacuum degassing and pressure casting to eliminate bubbles https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/0bc29058-6aad-4234-ae4a-87cb2467580a/20210722_153706.jpg Home During COVID lockdown when a client's lab was shut down I designed and built an open loop air dehumidifying test setup in my shop. I was able to heat, cool, and humidify the air as needed to test new dehumidification technology https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/363e9c17-b979-4944-b72b-b5480081a533/IMG_8997.jpg Home I was co-lead on the design and lead of testing for this hydraulic 6DOF robotic arm. Lead a small team of engineers through the design stage. Then planned out the testing matrix to strategically load the arm from gripper back to the base (design loads and then destructive). Then performed the full product release including drawings, BOMBs, and special assembly instructions. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/4e3e5087-2f2c-402d-8dbb-c0a046ea27d5/IMG_8693.jpg Home Management of hydraulic lines is a challenge and on this project there were a ton of lines going all the way through a 6 foot long robotic arm. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/bb1d0869-1bbd-443e-8f14-cf89c434e567/20250304_142352.jpg Home I designed the part and mold for this chopped carbon fiber part. This one was just a fun project excuse to play with carbon fiber compression molding. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782422990230-IQJGMGH6EX5Z69J6FDZ5/20240114_191919.jpg Home I CNC machined and glued up this foam lamination mold for the local Formula SAE student race car seat mold. They still use the seat today! https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/678db78f-6596-4f6c-8cca-76becceaa7a9/Exhuast+ejector+tool%2C+4-13-07+%282%29.JPG Home One of the larger carbon fiber lamination molds I have designed. It is a tail cone for a carbon fiber unmanned jet. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782420610817-9OJKNRZ9EB669XYOW17R/DSC00001.png Home An old school low-tech mechanism to overcome slow speed drive shaft misalignment is called an Oldham coupling. I designed one and this milling machine fixture to test it. We were able to misalign the axis accurately with the X axis and DRO to see how far out of alignment we could get. I love a good simple test set up... https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/57f56a80-4dac-4b26-99f9-76ab63c34aea/DSC00016.JPG Home This is one corner of a rolling carriage with a 30 ft crane on top. The hydraulic actuator hidden in the main side member extends to raise the carriage up and retracts to lower and pull the brake pad up and clamp against the I beam the whole thing is rolling on. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1641639e-1474-4649-9eeb-5663600374b9/IMG_2501.JPG Home A machining fixture for a carbon fiber molded part made to fit on the 4th axis. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/7bcf21dd-416e-4aa4-8392-b36f448067a6/IMG_2498.JPG Home A machining fixture for carbon fiber parts using shoulder bolt pivots to enable part loading and locking toggle clamps to hold the part in position during machining https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/56baa142-04a5-4ce6-83fe-435644300954/IMG_3997.JPG Home My first experience with die casting. A relatively small part with lots of features and curves that required a decent amount of machining after casting. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/2dcea224-4843-4f9a-9031-63de8f91397e/DSCF0059.JPG Home I designed the large cross-braced crane structure of this folding launch and recovery system, including FEA of multiple load cases in multiple configurations. Also kept a detailed spreadsheet of all components and positions so I could design the rigging to ensure a level lift. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/3ca79c79-5430-4783-8bbe-8019f3589a9d/DSCN0011.JPG Home I love a good test fixture and this was a good one. Testing different ball bearing types in varying levels of contamination. ISO certified grit was used to ensure consistent wear. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/f8e73530-ae1c-49b3-826e-76aec1fbca2a/DSCN0730.JPG Home Spec'd, installed, and designed the PCB holders for a thermal shock test needed to find weak components before they were potted into their housings. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/7c225655-cc4d-4bb4-a2b8-8dfabd72017c/IMG_0124.JPG Home Was sent by a client to Hong Kong for 2 weeks to assist in bringing an assembly line up to speed on a new product. A great learning experience and one I would like to do again...as long as it's in Business class ;) https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/b0de63dd-01f5-45e4-929d-eedac90a13fe/IMG_0292.JPG Home I was not involved in the design of this product but was brought on board to figure out alignment issues they were having. It turned into a welding fixture and process refinement process. Tight positional tolerances on a fairly large weldment takes a lot of testing and patience! https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/989d9e97-bc69-4782-bb8f-4f6305dfe96d/IMG_20160518_171031.jpg Home I really enjoy designing and testing assembly fixtures and aids. Making sure everything assembly staff need is in the right place and reconfigurable as needed is a very satisfying design challenge that often gets overlooked. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782420582780-KW24MNSY861OAUPRHZEB/20220128_113719.jpg Home I don't design PCBA's but I have packaged quite a lot! For this project I also designed the buss bars used to deliver power to all of the boards. Ease of assembly and taking tolerances into account were key. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782422815485-41SMEQO5KYZX1JJ17JRR/0731190821.jpg Home I have occasionally worked with companies to prepare demo hardware or presentation kits. In this case I designed and fabricated the CNC machined foam and sheet metal panel for a hydraulic pump test station that fits in a pelican case. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782422850660-FQPB8KY7S1FRHHZPB9AB/1214170958.jpg Home A collection of 3d prints for one project in the early stages of development. With 3d printing being as cheap and convenient as it is now there's no excuse to not explore every option quickly. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/6efe2ce0-4eb9-4956-96c7-802c636b530a/DSCN0180.JPG Home Working with the electrical engineers to find the key components to test, I have dug my way through my fair share of potting epoxy to test electrical components. I'm never afraid to get my hands dirty. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/7da87d20-d23f-4f75-b97f-c77bbbd97f53/DSCN0209.JPG Home Close up view of another post mortem excavation on a potted PCBA to find the failed component. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782422886565-UFMD1QPCXOIJ9YGE5ABV/IMG_0504.png Home Getting the most out of a custom aluminum extrusion sometimes requires two extrusions. These two get machined separately https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782422916386-NCBSS6W8T0IYKQAFMBPP/20201215_173012.jpg Home A quick and dirty adaption of a handheld refractometer to be able to evaluate a constant flow of liquid. Test fixtures only need to be as fancy and expensive as they need to be! https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/0d236375-8578-483e-a827-fd3dff84bb07/20210615_174723.jpg Home A custom designed and manufactured, machined plastic, and molded silicone gasket fluid distribution grid. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782422965856-OVDWTFOSZFOA9E7IAD2I/20220728_201214.jpg Home I do occasionally do a small manufacturing run of custom parts I design. I'm not looking to be a machined shop but I can do a quick turn on small batches https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782423012243-DS2KWVOYUTYC838L6U7I/0108191309.jpg Home I love a failure investigation of any kind of mechanism or machine. It takes a sharp eye and attention to detail to decode the puzzle. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782423027613-029MCF69CNREBNVL9MUN/0506191051.jpg Home sometimes you just have to do a quick test to figure out when and how a part will fail or perform under load and I have whipped up quite a few test fixtures very quickly over the years https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/1782423073611-GGKVIFHDUC50AFNTUKUY/0813181102.jpg Home Safety is important! Especially when testing at high pressures. I am always looking out for everyone's safety even when it's not this obvious https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/d51b72ca-309e-47a7-b556-ce34222ea19c/IMG_4036.JPG Home I love visiting vendors to be there when parts are made/cast the first time. This was a rather large die cast part that had many challenging design and casting aspects. It took a while but we got there. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/ea5072c2-6afd-4d54-a93c-9d0181cc1c06/TBD_logo_BOMB+ver+4.png https://video.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/b13a1478-cfa2-4473-8e2e-4e4731d1838c/playlist.m3u8 https://video.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/b13a1478-cfa2-4473-8e2e-4e4731d1838c/thumbnail Home Home