Laser-Safe Enclosure
A sheet metal enclosure for an industrial additive manufacturing system
Affiliation:
Alloy Enterprises Co-op
Role:
Time Range:
Primary Mechanical Design Engineer
2022
Skills:
Mechanical Design, CAD (Solidworks), Complex Assembly, Sheet Metal, Laser Safety, System Integration, Vendor Communication, Tolerance Analysis, Aesthetic Design, Coatings, Technical Drawing
Background:
This was a project to create the enclosure for a novel industrial additive manufacturing machine that involved laser-cutting and stacking thin layers of carefully prepared aluminum sheets. As a machine with a powerful laser, the enclosure for the system had numerous additional requirements to ensure safety and appropriate sealing. I was tasked with finalizing the design for the enclosure, which involved a large number of sheet metal panels and bent support posts. This design involved many components, and as such involved tolerance analysis and design for assembly considerations. The enclosure also housed and supported numerous auxilliary systems for the machine, which I had some involvement in designing and integrating.
Images:
My Contributions:
• Designed sheet metal panels and struts with inserts for enclosure
• Designed viewing windows with laser-safe glass
• Worked with laser-safety contractors to ensure light sealing property of design
• Integrated enclosure with existing frame
• Integrated and designed material I/O port to allow sheet stock to enter without letting light escape
• Designed sensorized enclosure doors to allow for maintenace and part removal
• Integrated enclosure with auxilliary subsystems and auxilliary I/O
• Helped build and assess first article of the machine
Outcomes:
This project has been deployed in the ongoing construction of alloy enterprises' first industrial manufacturing center. I have received feedback that their engineers and management has been happy with the performance of the enclosure.