https://www.thoughtbombdesign.com/home daily 1.0 2026-07-09 https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/ed69714c-2cbe-4c2d-ab8b-abddedcf82d2/A2.jpg Home I had the opportunity to work with a great team from IDEO as a client on a fairly large project. They came up with an amazing design and we fought hard to keep the vision. I still keep in touch with the IDEO team and I'm happy to report they are super pleased with what we released. https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/b83c324c-80c0-4ef4-bac9-6e9d4b07a6c9/atlas.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/v1/6a3d86339058312e26167430/1782433201068-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/v1/6a3d86339058312e26167430/3530aeab-c706-4278-973a-55b8163ae173/Kuri.jpg Home On the Kuri Robot project I took most of the head design from prototype to production. Lots of little details getting the main head panels to align perfectly and repeatedly, a lot of electronics and mechanisms to design and house, and even eyelids! ;) https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/74880618-e1ad-471d-96fa-71bbea56d633/cycle+tester.jpg Home I designed and built this cycle tester to compare lifecycles of different latex band manufacturers, sizes, and many other factors that would have been impossible to test in the field https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/5aa9eb5b-112f-40d6-b4e1-35addd9acc1b/formlabs+4L.jpg Home I have a large scale SLA formlabs 4L 3D printing systems in-house allowing very quick turn around on prototypes https://images.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/6d316a3c-2456-41ce-9ac6-38864b1d2d69/garner.jpg Home I love a good mechanical challenge, and this was a fun one. The client only wanted to use one motor (the conveyor motor) to move the payload and then push it at 90 degrees straight down a chute to the right in the image. The solution was the spring loaded oddly shaped piece on the left with the rollers that gets pushed on by the payload and pivots to push the payload to the side. Simple and reliable. 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/dedf346b-112d-4424-9898-7e60a85c930d/robot+finger.jpg Home I have had this project kicking around for a while and eventually I will get around to finishing it. I am making an SLA printed robotic hand with tendon based actuation at each joint. Once I am happy with a finger design I'll move on to the super complicated palm.... 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/v1/6a3d86339058312e26167430/1787f628-0373-431b-a6fe-5c62cc4e5b4e/Model+Mania.jpg Home In 2009 I won the annual Solidworks competition for speed and accuracy at Solidworks World. 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/v1/6a3d86339058312e26167430/9f493a3e-b4fb-437e-ac1f-0144dd3f308f/burning+man.jpg Home I have also had the opportunity to work on some purely fun projects like this fire pit for Burning Man! The clients reached out to me with some pencil sketches and after some back and forth I sent them a dxf of the parts to get laser cut and some simple diagrams of how to assemble it. They loved the picture speaks for its self 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/d39bf72d-33f0-42c1-b11b-a3ce78d36491/art.jpg Home If you have a CNC in your shop you have to play with it right!?! I used some scrap 1" thick acrylic to make this relief patterned wall art. I machined away a level at a time and painted inbetween to end up with what you see. I have lots of sketches for more ideas that I'll get to in all my free time! 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/e6be5017-ab9c-46b9-baa4-aa562f396ec5/salinity+tester.jpg Home With the right clients sometimes you get to play mad scientist, and this was one of those opportunities. Without getting into the details, I came up with 4 different ways to measure the salinity of water in ways that would be way cheaper than the many thousands of dollar equipment they planned to use. I loved planning out the tests and analyzing the test results, I just couldn't quiiiiite hit the accuracy of the expensive one. 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/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/v1/6a3d86339058312e26167430/1782420582780-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/v1/6a3d86339058312e26167430/1782422965856-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/ea5072c2-6afd-4d54-a93c-9d0181cc1c06/TBD_logo_BOMB+ver+4.png https://video.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/13b48121-83e1-49ea-bce4-57514d947f8e/playlist.m3u8 https://video.squarespace-cdn.com/content/v1/6a3d86339058312e26167430/13b48121-83e1-49ea-bce4-57514d947f8e/thumbnail Home Home