Engineering

Design

Matt Baum

Matt baumI want to be a part of designing the future and conceiving new ways for us to thrive in the 21st century. In my work I seek to combine an understanding of function and mechanics with an appreciation of form and beauty that I have cultivated through my studies of both engineering and design. I have developed the skills to engage in every stage of product development. I enjoy design research, product ideation and sketching, 3D modeling and rendering, and prototyping and manufacturing. I am excited and inspired by the innovation taking place at the heart of design culture in areas like renewable energy and sustainable design, new forms of transportation and urban planning, and human-centered products that connect us to our technology and to each other. My goal is not merely to produce and sell more consumer goods, but to create meaningful new ways for people to live and societies to function.

ContentsMachine DesignMachined Aluminum Motor MountSheet Metal Motor MountInjection Molded Nylon Motor MountDVD Return Slot Assembly

Product and Business DesignModgardens

PrototypingHeavy Lift Octocopter3D Printed Impeller

Social DesignCircular ProductionToyota Production StagesA Nation in Crisis

Resume

machine designSolidworks 3D ModelingDesign for ManufactureMechanical Systems Design2D Part DrawingsGD&T

motor mountpart designThese motor mounts were designed in a machine design class to gain experience with design for manufacture. Three different motor mounts were designed based on the manufacturing technique: machining, sheet metal, and injection molding. Each part model took into account the manufacturing steps necessary to produce the design. The assembly models are toleranced based on GD&T standards. The motor mount was designed to fasten the motor of an archive data storage system to a flat tray surface to maintain proper gear alignment. The primary functions of the motor mount are to: a) rigidly support the motor shaft bearing (aligns motor to gears) and b) incorporate two bearing holding tabs.

machined aluminumDesign

The design has a thick front surface that is fastened to the shaft alignment part on either side of the motor shaft bearing, providing reliable alignment and stability to the motor. Two pins on opposite corners of the part serve to position the motor mount relative to the shaft alignment part. The hole and slot that accommodate these pins are drilled blind but are designed with generous depth tolerance. Fastening the motor mount to the shaft alignment part using two screws on the sides of the part (in addition to the fastener on the corner flange) avoids the excessive material removal that would be required to fabricate flanges for an entirely top-down assembly.

Manufacturing

The motor mount requires 4 different machining directions and begins with a 1.5in3 block of solid aluminum.

Direction 1: Bottom Surface -Grind surface to 1.117in-Remove material using a 1/2in tool-Mill pin holes using a .093in tool and drill clearance hole for fastener using a #5 drill bit

Direction 2: Front Surface -Drill holes using 5/32in drill bit. Bore center hole to 0.189in to accommodate motor shaft-Mill flange using 5/64in tool

Direction 3: Right Surface-Grind surface to 1.354in-Mill flange using 5/64in tool-Mill corner tab using 5/64in tool-Drill fastener clearance hole using #5 drill bit

Direction 4: Back Surface-Grind surface to 1.437in-Drill fastener clearance hole using #5 drill bit-Mill cutout using 5/64in tool

Analysis

Deflection at load:

δ=(Fl^3)/3EI h^3=(4Fl^3)/Ebδ h^3=(4(75lb)(0.478in)^3)/(10e6psi(0.315in)(0.0118in)) h=0.096in

Bending Stress:

σ=(Fl h/2)/I σ=6Fl/(bh^2 ) σ=(6(75lb)(0.478in))/((0.315in)(0.096in)) σ=29638psi

Tensile yield strength of aluminum 6061-T6 is 40,000psi.

Assuming a deflection of 0.0118in (based on deflection of previous part) and using a tab thickness of 0.096in resulted in an applied force of 75lbf and a bending stress of 29,638psi. This is well under the tensile yield strength of 40,000psi.

Back view of motor mount

sheet metalDesign

The chosen design is simple and efficient, using a minimal amount of folds and material. Flanges were created to accommodate the pins and fasteners, and tabs were created to hold the bearings in place. The tabs have a spring-like form to maximize their ability to withstand deflection. A vertical tab of material directly below the motor shaft bearing serves as a datum feature and maximizes the accuracy of the bearing positioning. A pin and slot on opposite corners of the part serve to position the motor mount relative to the shaft alignment part. Two M2 SHCS screws are used to fasten the motor mount to the shaft alignment part. The part is stamped from a 63mm x 83mm sheet of 16 gauge (1.651mm) steel and folded into shape.

Manufacturing

Part begins with a 63mm x 83mm sheet of 16 gauge steel. Flat pattern can be nested with spring tabs overlapping to save material.

1. Stamp or laser cut 63mm x 88mm sheet to form flattened shape of part.

2. Pierce fastener holes, sized to fit 1/16” dowel pins and M2 fastener screws.

3. Fold sheet into final form of part(possible order: a) 2 folds to form 3 base sheets that accommodate motor b) fold positioning and securing tabs c) fold spring tabs.

4. Touch up and finishing. Remove sharp edges.

Analysis

1. The tab structure was simplified by considering the horizontal distance of the bent tab to be the effective length.

2. Initial tab model experienced a total deflection of 0.254 mm.

3. Goal seek was used to deter-mine the force needed to match this assumed deflection.

4. The force needed, 56 lbs, caused yielding in first iteration of the spring tab.

5. Length of tabs was adjusted to reduce deflection.

6. Stress analysis was done on each individual tab to insure yield-ing does not occur.

Result: to reduce stress on the tabs, the tab lengths were adjusted to produce 34.2 lbs of force with a total deflection of 0.115mm.

Motor mount installed in assembly to secure motor shaft and bearings

injection molded nylonDesign

The chosen design has a curved nominal wall that follows the form of the motor shaft to reduce the size of the part and the material used. The tabs that accommodate the fasteners and hold the bearings in place are projections off of the curved nominal wall. The curved nominal wall and the tab projections are designed with a uniform thickness to facilitate an even injection of material. Fillets have been added to all of the sharp corners of the part to make them easier to fill and avoid high molded-in stresses. Ribs were incorporated into the tabs to add support and rigidity. Two pins are built into the tabs on opposite corners of the part to position the motor mount relative to the shaft alignment part.

Analysis

The deflection of the tab was computed using a cantilever-end load condition, and the stress of the tab was calculated using the bending stress equation. A tab deflection clearance of 0.020” was assumed in order to calculate the corresponding force needed. The material chosen for this part was Nylon. The Nylon has a yield strength of 12 ksi. The maximum stress the tabs will have is 10.5 ksi, so the tabs should not fail.

Manufacturing

The core half of the mold forms the underside of the curved motor enclosure and creates the bottom features of the part (colored in green), and the cavity half of the mold forms the top features (colored in blue). The gate is located in the center of the top surface of the curved enclosure, since this surface is the nominal wall and the central location of the gate will allow an even flow of material into the projected walls. A side action is used to create the cutouts for the clearance hole where the motor mount attaches to the motor, and for the hole that accommodates the motor shaft bearing. The inside surface of the part has a 2 degree draft angle to allow a smooth separation of the core and cavity, and the ribs have a 1 degree draft angle.

Motor mount installed in assembly to secure motor shaft and bearings

DVD REturn slot assemblyThe DVD Kiosk Return Slot is designed to accept a DVD returned by the user. It feeds the DVD back into the machine to a point where a “picker” can grab it and file it into the correct location within the machine. The Return Slot is mounted on the inside of the overall DVD Kiosk and is only visible by its very front slot where the user returns the DVD. The design uses a drive system consisting of two shafts driven by one stepper motor to move the DVD along its intended path. Two gates within the Return Slot interpret signals from the electronics system that determine whether or not the DVD will be accepted into the drive system. Most of the parts were obtained from McMaster Carr. Part drawings are included for the parts that have been custom designed and must be manufactured. The assembly model is toleranced based on GD&T standards.

DVD return slot assembly

Position 1:

The user inserts the edge of a DVD case inside an injection molded slot that extends outside the DVD Kiosk. Four Fairchild phototransistors detect a valid DVD case and send a signal to two solenoids to open the primary gate. At this point, the DVD case must be pushed by the user past the first gate in order to contact the initial drive roller. The rollers are driven by a Lin Engineering 4218 High Torque Stepper Motor, and both rollers are connected with a belt/gear system.

Position 2:

Once the DVD case is in contact with the first roller, the DVD is moved along a sheet metal support rack past the vicinity of the first gate. It is constrained horizontally by cylindrical spacers. At this point the DVD is detected by two Agilent HSDL-9100 sensors that send a signal to all four solenoids to close the primary gate and open the secondary gate. Each gate is detected by two Omron EE-SX1041 sensors that interpret when the gate is open or closed.

Position 3:

The DVD case is moved into con-tact with the second roller which drives it past the vicinity of the second gate. Once two final Agilent sensors detect that the DVD case is past the vicinity of the second gate, a signal is sent to the picker to grab the case from the Return Slot.

Exploded view of assembly

GD&T part drawings of injection molded DVD instertion slot GD&T part drawings of sheet metal support structure

product & business designProduct Concept SketchingSolidworks 3D ModelingKeyshot RenderingBrand StrategyFinancial Analysis

modgardensModgardens was developed in a product and business design course that brought together LMU entrepreneurship and OTIS design students in an incubator setting. The project was inspired by vertical farming, which uses hydroponic greenhouse technology to cultivate crops in skyscrapers or on vertically inclined surfaces. With over 80% of the world’s population estimated to live in urban areas by 2050 and limited farmland available to feed the growing population, vertical farming could become a viable option for food production. Modgardens is a modular vertical farm and shelving system designed for wall installation in urban dwellings. The project deliverables include a working prototype, the product functions and specifications, the engineering and design, the manufacturing process and cost, some projected financials, and the branding and sales strategy.

modgardensHex Shelf Module Half Hex Shelf ModuleHex Garden Module

Sample Assemblies

Modules Price

Hex Garden

Hex Shelf

Half Hex Shelf

Drag and drop modules to create your own modgarden

Size

Harvest

Hex GardenHex GardenHex ShelfHex Shelf

$120$120$60$60

Total $360

28 in x 35 in

2 salads / week

Your Assembly

Move Rotate

Online User Interface Mounting Hardware

Wiring Diagram Components

LED Ultra Violet LightPlant / Flower / Herb

1/4” Glass Garden BasinNutrient Filled Hydro Pearls

Original Sketches

The Story

In an increasingly urbanized world, more people are living in small spaces in cities.

These city dwellers are in search of ways to make the most of their limited living space.

Small urban living spaces often lack the presence of plants and trees. Limited light and space make it difficult to grow indoor plants.

Mission Statement

Modgardens gives customers a way to add customizable shelving to their walls and producefresh and healthy food.

modgardens

Small-scale, modular vertical farms for urban dwellings.

Includes three modules to offer shelving and a system to grow plants.

Customers can create their own arrangement to fit their available space.

Product Specifications

LED flexible strip grow lightsHydropearls in glass plant bedWall mounted or free standingLights connect using 2.1x5mm power jacks Wood frame Create custom arrangments with 3 different modules

The Market

Eco-conscious and design savvy customers in urban dwellings (especially small apartments in big cities)

Major urban markets: Los Angeles, San Francisco, Portland, Seattle, Denver, Chicago, Boston, New York

Product Costs

Competitive Advantage

Competitors do not offer:

ModularityShelving spaceWall mountingSculptural design

Wood

LED Grow Light

Hydropearls

Glass

Hardware

Electrical

Labor Total Cost

Retail

$8

$1

$2

$4

$5

$2

$30 $52

$120

Hex Garden Module

Wood

Hardware

Labor Total Cost

Retail

$9

$5

$15 $29

$60

Hex Shelf Module

Wood

Hardware

Labor Total Cost

Retail

$6

$5

$10 $21

$40

Hex Shelf Module

Modgardens brand strategy

PrototypingManual MachiningSolderingWiring and ElectronicsUse of Power ToolsRapid Prototyping

Heavy LiftOctocopterQuadcopters have been undergoing a consumer renaissance as they have become more affordable and accessible than ever. The many potential commercial applications of quadcopters are still being explored, in areas such as search and rescue, structural surveying, security and law enforcement, media and broadcoast, and environmental protection. In early 2012, Congress told the FAA to write regulations concerning commercial drones by 2015. When that happens, businesses will have clear guidelines for manufacturing, operating, and selling drones. This recent surge in interest in Unmanned Air Vehicles (UAVs) led the American Society of Mechanical Engineers (ASME) to make UAVs the basis for its 2014 student design competition. The competition scoring system encouraged copters that could lift a heavy payload. In order to

maximize the cargo carried and earn the most possible points at the competition, the lift of our propulsion system was optimized. Our UAV was designed as an X8 octocopter, a craft with two coaxial propellers on four different arms. The frame and protective shroud were constructed by hand, and the components were chosen according to our own design. No preassembled kits or existing designs were used.

Payload carries disproportional amount of points. The competition defines the payload as the weight of cargo plus the weight of the craft itself. A lightweight craft is therefore not necessary or ideal.

Limiting factor for maximum payload is lift possible within the given size requirement. Goal is therefore to design for as much lift as possible within given dimensions. Lift is primarily determined by the motor power and propellor size.

A coaxial design adds a 50% increase in the copter’s lift. With two stacked arrangements of four propellors, the maximum possible propellor size is 15”. The motors are chosen to power selected propellors. The rest of the electrical components (speed controllers, batteries, wire gauge) are chosen based on the motor requirements.

Maximize Weight Maximize Lift Within Size Requirement

Coaxial OctocopterDesign

Design Optimization

The frame, motors, speed controllers, and batteries were all chosen based on the ultimate goal of maximizing lift. The size of the frame and propellers were the basis of the design for the entire system.

The propulsion system consists of eight propellers, eight motors, eight electronic speed controllers, and four batteries. The power system connects all four five-cell batteries in parallel and then distributes this power evenly to each of the motors. The power is then distributed to each motor’s individual speed controller (ESC), which receives a signal input from the flight controller and regulates the supplied power to its motor.

The signal side of the control system runs through the flight controller. The control board receives signals on four channels from the receiver (RX) which is sent to it from the transmitter (TX). It then processes these directional controls of throttle (CH1), roll (CH2), pitch (CH3), and yaw (CH4) along with readings from its instruments. Unique signals are then sent to each of the eight ESCs through eight outputs on the control board, supplying the appropriate amount of power to the motors in order to carry out the controls received from the transmitter.

The control system is run on MultiWii V2.3 code, open source code available online that supports a number of different copter configurations, from simple tricopters to coaxial octocopters. This Arduino code was edited in order to properly control the motor configuration and components of the UAV, and then loaded onto to the control board through a micro USB connection. The control board processes and settings can be viewed and adjusted through a graphical user interface (GUI) on a laptop. Through this interface, it is possible to monitor and calibrate the copter’s instruments, set auxiliary channel controls, select flight modes, and adjust PID settings, which govern the self-stabilization of the copter.

3D printed impellerAn impeller was designed for optimum performance based on fluid dynamics theory. A 40 degree backswept flow exit angle, the maximum blade height, and required outside diameter were given. The flow inlet angle, inner diameter, and number of blades were determined. The chosen design was then modeled in Solidworks and printed on a Stratasys rapid prototyping machine. The 3D printed model was tested in a blower, and the experimental results were compared to theoretical data on impeller performance.

Social designIdea WebsProduct Life CycleSocial Context of Design

I am passionate about using design to create positive changes in the way people live and societies function. I have put considerable thought into the role of design in the modern world and what needs can be addressed by designers, including transportation, food production, urban planning, and alternative energy technologies. It is important that as designers we ask: Are the things that we design really making an effect and making change? For much of design no longer operates with the good of the consumer in mind. Its goal is to produce and sell more consumer goods, not to make people happier, safer, more comfortable, or more efficient.

In the diagrams that follow, I explore the ways in which we produce and how production can be made more sustainable; the impact of the different stages necessary to bring a product to market; and some of the major social issues we are currently facing in the United States.

Circular Production Toyota production stages

A nation in crisisMajor Social and Political Issues in the U.S.

Matt baum

Loyola Marymount University, Los Angeles, CaliforniaBachelor of Science, Mechanical EngineeringGPA: 3.3LMU Honors Program and Presidential Scholar

SKillsSolidworks ModelingKeyshot RenderingDesign for ManufactureTechnical Drawings (GD&T)

Product MockupsRapid PrototypingManual MachiningSoldering

Design ResearchConcept SketchingIllustratorPhotoshop

Relevant courseworkProduct and Business DesignMachine DesignComputer Aided DesignHistory of Design

Social DesignMaterial Selection in DesignMechanics and MaterialsFluid Dynamics

Statics and DynamicsThermodynamicsCircuitsEnvironmental Science

830 Cheltenham Road / Santa Barbara, CA 93105 / 805-448-9905 / mattwbaum@gmail.com

education

Work experience

Lifestyle Design, Santa Barbara, CA - Industrial Design Intern

Lifestyle Design is a design agency that offers strategic branding, strategy, product design and packaging design services. While I was interning with Lifestyle Design I participated in the reconception of the brand strategy for one of their major clients (House of Marley), helped produce new graphics and renderings for a line of headphones (House of Marley), and helped conceive and model the form of a new portable speaker (Respectify). I gained experience with 2D ideation on paper and in Illustrator and 3D modeling and rendering in Solidworks and Keyshot, and learned about design for manufacture, product pricing, marketing strategy, and brand strategy. My experience at Lifestyle Design helped me to understand product design and strategy. It made me more capable to work alongside designers as a mechanical engineer.

Neal Feay Company, Santa Barbara, CA - Engineering Intern

Neal Feay is an aluminum manufacturing company that designs and manufactures high-end audio equipment and furniture. While at Neal Feay I gained exposure to the entire production process of a product: beginning with rough pencil sketches and evolving into a dimensioned CAD model, the interaction between the engineers and the machinists to correctly machine the part using CNC routers, finishing the part (sanding and coloring), and shipping the parts to customers. This experience gave me a clearer picture of the context in which engineers and designers work as it relates to the rest of the production process.

Summer 2013

Summer 2012

Matt BaumDesign Engineermattwbaum@gmail.com805-448-9905