Work

Projects and design studies, personal and professional.

Selected Work

Repair / Machine recommissioning

Corroded sealing faces on a used machine, rebuilt flat in-house against a months-long lead time.

Design study / Reverse engineering

From a scanned accessory connection to a custom, wall-mountable dock.

Redesign / Metal additive manufacturing

A worn latch was failing the machine's pressure and purge tests. Shortening it fixed them.

Structural analysis / Verification

A 10,000 lbf load case, and a factor of safety of 0.507 that turned out to describe the model.

Design study / Reverse engineering

Remotes of different shapes. Scanning each one and the table they sit on gave the geometry for one holder.

One-off parts and small repairs.

Amp wiring and headliner, 2009 Honda Accord
In my Accord I wired a four-channel amp for the door speakers and a mono amp for the sub. When the connections in the Rockford Fosgate amp stopped working, I took it apart and cleaned it inside, and it worked fine afterward. The headliner was sagging, so I took it out, wire-brushed off the gooey residue the old material left behind, and covered it in new suede.
Bed sensor repair, FlashForge Adventurer 5M
The bed level sensors failed, so the printer stopped getting a probe measurement and kept driving the head into the plate. I stripped it down, cleaned the boards and connections, and retightened the belts. Reinstalling the pressure sensors was the real problem: with no factory torque spec I could not reproduce the original preload, so rather than guess I ran a system recalibration and let the machine re-zero against the torque I had actually applied. It has printed correctly since.
Filament shelf brackets
I found a filament holder design online, liked the idea, and modelled my own rather than printing theirs. The original was built around 28 mm timber, which is not a size a US hardware store sells, so the bracket had to be sized around dowels I could actually buy. A small printed collar checked the dowel fit before I committed to a pair of brackets.