Formlabs Projects
Form 4 Functional Parts, Fixture Development, and Auxiliary Equipment Prototype
Affiliation:
Formlabs Co-op
Role:
Time Range:
Primary Mechanical Design Engineer
2023
Skills:
Mechanical Design, CAD (Onshape), Injection Molding, Die Casting, High Volume Manufacturing, Product Design, Snap Fits, Selective Laser Sintering, Conceptualization, Low-Cost Design, Appliance Design, Lifetime Testing Fixtures, Manufacturing Fixtures, Inspection Fixtures, Mechanical Property Testing
Background:
This encompasses a number of projects I worked on at Formlabs, including several parts for the Form 4. I also worked on a number of fixtures and jigs related to the Form 4, including fixtures for lifetime testing and optical inspection. I was also part of a small team working on a first prototype for a future product. Much of this work involved information that is not yet publicly available, hence the vagueness of this entry.
Images:
My Contributions:
• Designed Form 4 SLS HDMI retention clip, with tolerance and fit testing and mock-repairs
• Designed injection molded Form 4 RFID sensor cover
• Designed injection molded Form 4 lid corner covers
• Built test fixture and performed lifetime testing for Form 4 lid
• Designed, tested, and used fixture for optical component fabrication
• Performed extensive mechanical property analysis and tensile testing to inform design decisions
• Designed parts for vacuum forming and heat forming
• Designed and built involved prototype for future product
Outcomes:
The parts associated with the Form 4 have since been deployed in thousands of machines delivered to customers.
The other projects are ongoing at Formlabs.