2. Table of Contents
Bio
Education
Design Study
Ensemble Module System
Samples of work
Automotive Battery Block & Module Design
Automotive Battery System Design
Flow Bench Design
Tooling Design
Drafting
Senior Capstone
Overview
Mirror Module
Final Assemble
Results
Contact Information
Jamison Micah Pezdek
3. Bio
Jamison Micah Pezdek
Born: August 6th, 1986
Hometown: Wynantskill, NY
Professional 6 years battery / automotive
Experience: 1 year product design
8 months medical device
4. Education
• Masters of Science,Computer Systems Engineering Focusing in
Computer Aided Design
• Class of 2012
• Coursework in CAD Design, C++ and Java Programing, Manufacturing, Energy
Systems, and Human Factors
• Bachelors of Science, Mechanical Engineering
• Class of 2009
• Minor in Business
Jamison Micah Pezdek
6. Design Process
Jamison Micah Pezdek
Design
Requirements
• What is the problem?
• When is it needed?
• What is the cost?
Brainstorming
• What have we done in the past?
• What are the issues with the current
design?
• What is required?
• What features would the customer
appreciate?
• What rules can we break?
Concept
Development
• What will it look like?
• What do we need to add?
• Do we know enough about the problem?
What is the science behind it?
• Do we have a backup?
• Develop a new block design that has a higher
energy density, for the same cost
• Timeline: 2 years
• Module assembly often consists of torqueing
many small screws in a tight space
• There was no defined system for packaging
the existing blocks
• Why do blocks need to be welded?
• Integrated HV Connection System
• Training to understand electrical point
connections
• Backup Welded Design
7. Design Process Continued
Jamison Micah Pezdek
Prototype
• What do we want to try?
• What areas should we focus on?
• How does it work?
Test
• What do we need to test?
• Do we need certifications?
• Where will it be used?
• How will the customer use it?
Analyze
• Did it work like we wanted?
• Did it break? Where?
• Did we think of all the possible outcomes
Redesign
• What didn’t we think of?
• What did the testing tell us?
• Can we make it effectively?
• Has all of the customers' requirements been met?
Test
• Did we test enough before?
• What has changed?
• Did things improve?
Ready For
Production
• Get parts ready for production
• Is the supplier making parts like we expect
• Are all of the tolerances correct?
• Prototyping with 3D Printer, Soft Tooling.
• Check for fit and form
• Automotive Standards
• Electrical Resistance
• Government Standards
• FEA
• Design Validation
Testing
• DFMEA
• Design Reviews
• Failure analysis
• DFM
• DFA
• Added features to enhance
customer experience
• Added features to enhance
reliability
• Further testing to verify
redesign
• Load testing to verify FEA
data.
• Vibration testing
• Hard Tooling
• FAI
• PPAP
• Process Validation Testing
8. Final Result
“The flexibility of the Ensemble system allows customers to design,
build and test a prototype pack in a fraction of the time it would
typically take for a fully custom solution. Next, the production quality
components used in the initial prototypes greatly reduce the pack
qualification effort needed to launch into mass production. Finally,
the same highly-reliable standard components used in the prototype
and development stages support a cost-effective launch of low,
medium and high volume packs without the need for expensive
tooling or a complex assembly line. Ensemble provides clear value
from project inception through high volume pack production.”
—Darren Bischoff, Director of Business Development and Marketing for Boston-Power
Jamison Micah Pezdek
12. Flow Bench - Testing
Jamison Micah Pezdek
Used for forced cooling testing
• Machined, COTS, 3D printed and
formed plastic components
• Achieves uniform flow rate across the
test chamber
• Swappable parts so flow rate can be
increased if the needa
14. Design Approach
Get as much information up front.
CRD, PRD
Design with simplicity and manufacturability in mind.
Have we done this before?
What are the real problems that need to be addressed?
Incorporate DFx early in the design.
DXF addressed material availability
DFX addressed design for assembly and manufacturability.
Tackled difficult design issues as a team in a room setting.
Brainstorming in a room is much more effective then through emails.
16. touch freezing device
•Used for sample preparation in
quick freeze deep etch microscopy
•Device rapidly cools biological
samples (10,000°C/sec) resulting
in vitrification
•Use of a linear motor and laser
curtain prevent mechanical
deformation
Jamison Micah Pezdek
17. mirror module
•Major component of
touch freezing device
•Houses four copper
mirrors, held under liquid
nitrogen
•Inclusion ofT-type
thermocouples allow for
monitoring of mirror
temperature
•T-6061 AluminumAlloy:
Ideal for low thermal
expansion
Jamison Micah Pezdek
18. final assembly
•Most machined parts
were done in house.
•The Mirror Module was
sent out to an outside
machinist.
•Construction and
Assembly took about
three to four weeks
Jamison Micah Pezdek
19. results
•Preliminary results were very
favorable
• Device effectively vitrified the leading
edge of the samples, ensuring quality
images
•Tests prove design as a working
prototype.
•Device is currently in use at
Northeastern University
•Water DropletTest
Jamison Micah Pezdek
20. contact
Cell: (518) 810-7736
E-mail: jamisonpezdek@gmail.com
Address: 15Wensley Street
Boston, MA 02120
Jamison Micah Pezdek
