dsmbiomedical_robert gibbons

FOR INTERNAL USE ONLY

Orthostructural Coop Experience

Robert Gibbons


Expectations• Designing Experience

– Completing real world designing projects

• Exposure in the Bio-medical Field– Discovering what a Mechanical Engineer can contribute

• Manufacturing Experience– Observing real world manufacturing practices


Designing Background• Drexel’s Classes

– Most recent class on Creo 2.0 was still very basic– Was useful for learning how to create models based off

drawings– Don’t teach how feasible a part is to manufacture– Don’t spend much time on GD&T terms

• Other 3D Modeling Software– Exclusively use Solidworks in my Formula SAE club at Drexel– Used Siemens NX 9 at my last CO-OP with Southco

http://www.solidworks.com/

https://www.google.com/url?q=http://www.janowiak.net/?page_id%3D159&sa=U&ei=WLgxU7LoDuPD0QH34YHoBQ&ved=0CC0Q9QEwAA&usg=AFQjCNFFbP6XHB0HKEAav58k7YEHzmtK9g


Screw Inspection Blocks

• Goal– Hold screws level on the

Keyence to inspect key features

• Result– Designed a fixture that

proved to be unsuccessful with metal screws, but could work for plastic screws

• Learned– How construction lines can be

helpful in the designing process


Starrett Angle Fixture• Goal

– View each screw’s helix angle– Easy to manufacture

• Result– Created a fixture that served

its function and proved versatile enough to act as a tabletop for other parts

• Learned– How to display different

scenarios in one assembly model


Alternate Views


Keyence Screw Rotation Pins

• Goal– Rotate screws on Keyence’s vise

while accommodating for screws with different drive features

• Result– Rotation pins which rotate screws

without slop – Replaceable tip feature which can

accommodate for new drive features in the future

• Learned– How to use modify an existing

fixture to preform in a new manner


Other Designing Projects

• Bone Plate– Accurately modeled a customer’s fully contoured

product based off of their 2D drawing– Used this model to create a DXF file to inspect our

prototype

• Plate Blanks– Created models and drawings for a family of

plates which eventually will be used to make the Bone Plates

– Modeled an existing machining pallet in Creo to be used in a tool drawing using a 2D drawing and visual inspection tools

• Indicator tips– Created tips with rounded blades to measure the

depth of screws with slotted drive features


Bio-Medical Field Exposure

• I already have experience with companies that were common workplaces for Mechanical Engineers, I wanted a different experience

• I quickly discovered the Bio-Medical field holds its self to a much higher standard than any other industry, typical tolerances to +/- .05mm or less.


Bio-Medical Field Exposure

• Machinery and overall capability of DSM to manufacture parts in house truly impressed me– Other industries I worked in always dealt with sending

their products over seas to be manufactured, and suffered through poor quality

• First time in a cleanroom• Manual inspection of each part produced


Bio-Medical Manufacturing

• Got to see the differences between machining plastic and metal

• Was a part of multiple polymer extrusions• Helped write documents which dictate the manufacturing

process– Routers – QA Procedures – IHR– DSS– Machining Systems


Manufacturing• I have only had real exposure to

manufacturing one-off parts, but here I was able to see and understand all of the background, set up, and fine tuning it takes to produce many parts in tight tolerance

• Still find it amazing how quickly parts can be produced on CNC machinery

• Was exposed to wire EDM, water jetting, 5 axis CNC mills, Swiss lathes, metal part de-burring processes, and other machines and processes which are used to make a final part


General Mfg. Support Tasks

• Preformed tasks including,– Weekly inventory update and bi-weekly TPT forecast

update– Analyzed labor reports– Request Tool, QA, and Part numbers– Placed Oracle requisitions for part orders


Basic Keyence• Never knew automated visual inspection systems existed• Basic measurements

– GK2 – Keyence Spring Plunger Vise– 2.0mm Drill Pin Tips


Keyence Operation


Keyence Programs• 2.7mm Trim-it Screw

– Created a program to significantly cut down on measurement time

• Cortex and Cancellous Screws– Helped design programs used

to measure key features including

• Major/Minor Diameter• Tip Radius & Angle• Overall Length


Keyence & Starrett DXF Files

• Keyence– Imported DXF files from Creo

to measure screw thread and head profiles

– Head profiles would be placed into an automated program

• Starrett– Imported DXF files from Creo

to measure screw thread and drive feature profiles


What I’ve Gained• Creo

– Real world experience – Bettered my drawing skills– New ways to 3D modeling

• Bio-Medical Field – High quality control standards– Very structured processes


What I’ve Gained• Manufacturing

– Holding tight tolerances over a run– Extruding and pressing polymer– Discovered the capabilities of many different

machines and tools• Keyence

– Experience with a powerful measurement tool– The importance of proper light and focus level– Gained insight to the next generation of part

inspection


Conclusion• Enjoyed my time here • Could see myself working in the Bio-Medical field

when I graduate• Learned a lot during my time here• Confirms my desire to use 3D modeling software

dsmbiomedical_robert gibbons

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