Mechanical Design

Over the years I’ve had the great pleasure of working on some amazing products between my time at Nest, Goddard, and Jawbone. Here you can find a brief look at some of the products, mechanisms, parts, and manufacturing processes I’ve worked with.

Detailed Design Studies

Full on design briefs with lots of detail:
Nest Cam IQ Outdoor
Nest Protect – 2nd Gen
Jawbone Up Move

Quick Snapshots

Shark Hair Dryer: CAD Architecture for product PCB keepouts, component placement, button interfaces. Wire routing, strain relief and cable overmolds Sliding mechanism design for "diffuser attachment" Legacy CAD cleanup, migration, and master modeling
Swab56 Proof of concept automated swab rolling machine: Prototype mechanism design, Quick iteration prototypes via 3D print, Client relations
Fall Protection Belt: Class 1 Med Device, hair trigger mechanism, soft goods, rapid prototyping, project management, EPM, PCB layout, client relations
Nest Cam IQ Outdoor: Mechanism Design, Acoustics Design, Hinges, Microphone design, Tolerance Analysis, FATP on site support, Ingress Protection, Cable design and overmolding, Injection Molding, Die Casting, LSR molding, Stamping
Nest Protect 2nd Gen: Reliability acceleration factor, Dust ingress prevention
Mini Jambox: Acoustic Design, Button and flex design, Acoustic sealing
Jawbone Up Move: Ingress Protection, Material Selection, Tolerance Analysis

Part Design Gallery

"Tumbler" - Die Cast, ADC12, Chromate coating + white paint
"Funnel Insert" - Injection Molded, PTFE Fiber Impregnated Delrin, As molded
"Funnel" - Die Cast, Zamak3, post CNC, as cast
Slip Ring - Electromechanical Assembly, injection molded, stamped, compression molded
Speaker Box - Electromechanical Sub Assembly, ADC12, 20% Glass Filled PC, Injection Molded, die cast,
Compression Spring - Wound, Spring Steel, 200N force
Speaker Box Face Seal - Compression Molded, Silicone Rubber
"Branding Iron" Die Cast, Aluminum A380, post machined, painted 2x
O Rings - Silicone Rubber
PCB + Light Guide
"Barn" - Die Cast, Aluminum A380
Light Guide - 2 Shot Injection Molding, PC
"Goblet" - Injection Molded, PC EXL 9330, Painted
"Rib Cage" - Die Cast, Aluminum A380, post machined
"Branding Iron" - Die Cast, Aluminum A380, post machined, painted 2x
"Tumbler" - Injection Molded Delrin 100
"Highball" - CNC machined Aluminum 6063, Bead Blasted and Anodized
Funnel Assembly

Processes

  • Injection Molding
  • Die Casting
  • Compression Molding
  • Sheet Metal Stamping
  • 2 Shot / Overmolding
  • Chemical Etching
  • Forging
  • CNC
  • Laser Cutting
  • Painting
  • Anodizing