1. Nathan Eastburn
Mechanical Engineering Intern
5/11/2015 – 8/14/2015

2. Overview
 Projects  What I Learned
 Advanced SolidWorks Skills
 Drafting techniques
 Manufacturing information
 IR Heater Digital Rebuild
 Task
 The Situation
 Progress
 Moving forward
 Endeavor Frame Redesign
 Task
 The Situation
 Progress
 Moving forward
 PRF Rebuild And
Improvement
 Task
 The Situation
 Upgrades
 Progress
 Moving forward
 Platen Rebuild And
Improvement
 Task
 The Situation
 Problems
 Progress
 Moving forward
 Standard Parts Creation
 Task
 Gallium SIM Parts
 Task
 Result

3. IR Heater Digital Rebuild
 Task
To build an accurate Endeavor IR heater attachment in SolidWorks from outdated
drawings and pictures.

4. IR Heater Digital Rebuild The Situation
 The IR heater was made by
SFI a very long time ago and
as such all the engineering
drawings for it’s components
were outdated and used
obsolete components.
 Using recent pictures and
old drawings I updated all of
the drawings to match
current demand and
available parts.
 I also made sure that my
models were accurate
enough to be used in
creating a build procedure.

5. IR Heater Digital Rebuild
 Progress
 Completed 3D models of all parts
 Completed 2D drawings of all parts
 Completed 3D model of Heater Assembly
 Completed 2D drawing of Heater Assembly
 Generated an accurate BOM from top level assembly
 Moving Forward
 Update current documentation
 Implement changes made to assembly
 Use assembly to update build procedure
 Utilize the above in the next Endeavor tool

6. Endeavor Frame Redesign
 Task
 Digitally capture the improved endeavor frame with expert precision.

7. Endeavor Frame Redesign
 The Situation
 Many changes had been made to the
Endeavor frame since the last
accurate drawings were produced.
 There were frequent corrections
being made with vendors over the
phone to ensure these changes were
upheld as the old drawings did not
show them.
 These corrections included cost
saving measures that save the
company hundreds of dollars on
each frame.

8. Endeavor Frame Redesign
 Progress
 Completed 3D model of frame
 Completed 2D drawings of frame
 Generated an accurate BOM from3D model
 Released updated endeavor frame drawings
 Moving Forward
 Update current documentation
 Implement changes made to frame
 Utilize the above in the next Endeavor tool

9. PRF Rebuild And Improvement
 Task
 Utilizing existing drawings, pictures, and build procedures; reproduce the PRF PM
lid in SolidWorks with accurate BOM structure, making improvements as needed.

10.  The Situation
 The PRF was the most complicated assembly I had worked on. Most of the parts
that were in the assembly when I got it needed updated, remodeled, or replaced.
And many simply weren't there. I used the existing build procedure and BOM to
digitally rebuild the assembly from the ground up.
 Upgrades
 Pneumatic fittings updated
 Aluminum manifolds
replaced with triple elbow
1 touch fittings & street elbows.
 1 touch T fitting replaced with
Y fitting mounted to the cover.
 Electrical weirs re-spec’ed
 CPC pins resized
 Solenoid orientation change
 Electrical diagram recreated
PRF Rebuild And Improvement

11.  Progress
 Completed 3D models of all parts
 Completed 2D drawings of sheet metal parts
 Completed 3D models of PRF Assembly, upgrades, & subassemblies
 Completed 2D drawings of PRF Assembly & subassemblies
 Generated an accurate BOM from top level assembly & subassemblies
 Moving Forward
 Update current documentation
 Implement changes made to assembly
 Use assembly to update build procedure
 Utilize the above in the next Endeavor tool
PRF Rebuild And Improvement

12.  Task
 Much the same as with the PRF I needed to rebuild this assembly however the lack of
documentation on the platen was prominent and as such I needed to collaborate with
manufacturing to ensure my assembly was accurate.
Platen Rebuild And Improvement

13.  The Situation
 I started work on the platen with only pictures and a severely outdated BOM to work with.
 After a few conversations with manufacturing I discovered a number of problems with the way
the platen was being constructed.
Platen Rebuild And Improvement

14. Platen Rebuild And Improvement
 Problems
 The bellows and pistons facilitating the actuation of the platen were improperly spec’d out As
a result the bellows was being over extended and compressed constantly causing it to fail.
 The finish spec’d out on the platen cover and many other aluminum sheet metal parts was
formulated using toxic hexavalent chromium
 The platen hub which acts as a rod connecting the platen to the actuator plate was being made
out of OFHC copper 101 which I believe to be an unnecessary expense.
 The drawing for the mounting cover was done poorly with many inconsistencies.
 The acrylic cover was being screwed to the cover panels without the use of PEM nuts or any
other type of fastener.
 The platen assembly was non-structured meaning it lacked proper subassemblies.

15.  Progress
 Completed 3D models of all parts
 Completed 2D drawings of sheet metal parts
 Completed 3D models of Platen Assembly, upgrades, & subassemblies
 Completed 2D drawings of Platen Assembly & subassemblies
 Generated an accurate BOM from top level assembly & subassemblies
 Initiated a company wide change for all part finishes containing hexavalent
chromium
 All upgrades and updates have been reflected on part models and drawings.
 Moving Forward
 Update current documentation
 Implement changes made to assembly
 Use assembly to update build procedure
 Investigate changes to bellows, pistons, and platen hub.
 Utilize the above in the next Endeavor tool
Platen Rebuild And Improvement

16. Standard Parts Creation Task
 As I worked through my main tasks
I frequently found that I needed
standardized configuration
controlled parts like screws,
pneumatic fittings, PEM nuts, and
wire terminals.
 These parts needed design tables to
effectively model hundreds of parts
all at once. Using the values in the
table to determine there
dimensions.

17. Gallium SIM Parts Task
 The engineering team lead requested that the teem create simple shape models for a
tool named the Gallium. He would use these models to create an interactive
controller for the tool. I was tasked with the process module and all its possible
configurations.

18. Gallium SIM Parts Result
 I managed to create all 71 process module configurations and add them to the virtual
Gallium tool within the week time frame given by the teem lead.

19. What I Learned
 Advanced SolidWorks Skills
 Routing (from to lists, tube creation, library management, trouble shooting)
 Design tables (advanced excel techniques, linking variables)
 Sheet metal parts (the continuity of error)
 Licenses management (swapping out the premium licenses on the fly)
 EPDM (part reference management and repair, work flow, vaults, advanced searching)
 Drafting techniques
 BOM (linking, omission, importance)
 Rev management
 Manufacturing information
 Sputtering processes
 Function of Endeavor
 Pneumatic methods
 Steel bellows
 Cable designations
 A bit of devnet and MAS
 Finishing