2. Table Of Contents
Tittle Page
Copper Coil Design – Diamagnetic Rotor 3
Stirling Fan 4
Forklift Design 5
Mastectomy Device 6
3D Printing 8
Custome Scaled RC cars 9
About me
My name is Marco Gonzalez, and I recently graduated from the University of Washington with a
Bachelor’s degree in Mechanical Engineering. I have been involved in projects the required
group work, independent work, and that incorporated a wide variety of engineering disciplines.
I am committedtoall projectsI am involvedinand I am certainthat I will make apositive impact.
3. MicrotechnologiesLaboratory –University of Washington
Copper Coil Design –Diamagnetic Rotor
Figure 1 SolidWorks drawing of coil design
At the Micro-Technologieslabinthe Universityof Washington,I designedand manufactured planar
coppercoilsforthe diamagneticrotor.One of the manufacturingmethodsthat Iutilized wasalaser
cutterto cut the shape of the coilson a thinblue tape placedontop of a thincoppersheet.Thiswas
done to create a negative image inorder toetch the exposedcopper.Ifirsthadtocreate a patternof
the coil designin SolidWorkstoprogramthe laser. Since the lasercutterwasnot precise and required
constantcalibration,asecondmanufacturingmethodwasrequired.Forthe secondmanufacturing
method, Iusedan etchingsolutionandprintedthe coil designthatIwantedontoa transparentfilm
usinga laserprinter.Since the inkusedby a laserprinterisa type of plastic, the ink washeatedand
transferred toa thinsquare coppersheettouse as a masking(negativeimage).Iwasthenable toetch
the surroundingcoppertoendup withthe desiredcoil design.Thismethodof manufacturingworked
well,butthe resolutionof the features wasnotaccurate enoughto meetthe desiredquality andto
produce the requiredElectrical MagneticFieldstocompare tothe theoretical models.Forthe third
manufacturingmethod,Itooka similarstepwithmetal deposition andhadtopurchase higherquality
transparentmaskingwiththe desiredcoil designs.Thisallowedme toget higherresolution detailsas
shownonfigure 1 and 2.
Figure 1 Etched coil pattern on copper sheet Figure 2Transparent film with coil designs
Figure 2 Desired coil patter for printing
4. Stirling Fan
For the ME355 manufacturingprocess classinthe Universityof Washington,there wasaproject where
it wasrequiredfora groupof twoto manufacture assigned partsfora Stirlingfan.My partnerand I
were assignedthree parts, whichincludedthe gaskets,piston yok,andthe displacementconnectingrod.
It was essentialtoknowhowtoread the dimensionsfromacad drawing,time manage the
manufacturingtime of eachpart,know how to use the machine shopequipmenttoefficiently
manufacture the parts,and constantcommunicationwiththe othergroupsthatwere taskedwiththe
remainingparts. Communicationwasvital inordertotestassemble the componentsforqualitycheck.
Figure 5 Connecting rod model
Figure 4 Gasket model
Figure 3 Piston Yoke
model
5. Forklift Design
For the ME 478 finite elementclassinthe Universityof Washington,there was aprojectthatrequired
the class to designaforkliftfork andto utilize ANSYStotestthe functionality.Idesigned a3D model of a
forkusingANSYSand SolidWorksmodeler.Afterdesigningthe forklift,I modeled alarge box and
assigneditmaterial toact as the weighttotest the forkdesign.Totestthe design,Ifirstleftoutthe
filetsatthe innerandouteredges.Thiswasdone to show that the filetshelpgetridof the stress
concentrationregions.Othertestsweredone,whichincludedchangingthe lengthandwidth tofindthe
optimal dimensions of the forkthatwould outputahigherfactorof safetyandlower overall stress
values.
Figure 6 Forklift testing on ANSYS
6. Mastectomy Device
For the ME490 SeniorCapstone project, myteammates andI decidedtodesignand manufacture a
workingprototype of adevise thatwouldmake iteasierfordoctorsto slice the breasttissue torequired
thicknesses formastectomytesting.We firststartedwithaproblemthatwas introducedbya
mastectomy professional inthe Universityof Washington,whichwasthatittakestoo longto train
specialists toconductthe procedure of slicingbreasttissuesintothe desireddimensionsfortesting. An
initial design wasintroduced thatresembled apinart toy. The designwasmodifiedbymygroupto meet
our desiredspecificationsdue tothe limitingfunding,material availability,andtime tomanufacture a
workingprototype. The pinswere tobe utilizedtoholddownthe breasttissue. We decidedtouse
plasticrods as the pins topreventdeformationof the breasttissue. The columnof pinswere separated
by thinslits,whichwere spacedouttoallow aknife toslice through. The distance betweenthe slits
were alsosetto be the same distance apartas the requiredthicknessof the sample breasttissue.This
allowedthe specialiststocutmultiple tissuesampleswiththe same thicknessesefficiently. Since the
slitswere toosmall tomanuallymanufacture,we received the assistance touse awaterjetcutter. This
allowedustoproduce the two guidingplateswithinanhourinsteadof days. The restof the parts such
as the base, the guides forthe pins,and screwswere manuallyproduced bythe group utilizingmill,saw,
and a CNC.Afterassemblingthe device,we headedtothe UW hospital tohave a mastectomyspecialist
testits functionality.Afterthe firsttrial withaspare tissue sample, the specialistconcludedthatitwas a
successful prototype designthatallowedhimtocutthe tissue samplestothe desiredthickness.Some
flawswere noticed,butfora prototype,he thoughtitwasa great accomplishment.
Figure 7 AssemblyDrawings of Mastectomydevice
Figure 8 3D assemblyof Mastectomy Device
7. Figure 9 Pathologist Steven Rath testing the device
Figure 10 Manufacturing top plates using mill
8. Rapid Prototypingd
For ME480 CAD class,there were a few Projects thatinvolveddifferent formsof rapidprototyping.First
assignmentinvolvedscanningaperson’sface andcreatinga face vase usingthe person’sside profile.
ThisrequiredSolidWorksinordertocrate the vase.I laterprintedthe vase usinga 3D printerand PLA.
Figure 11 Printing Face vase
Secondassignmentwas tocreate a moldof a person’shead.Todo this,Ihad to scan a person’shead
usinga phone app123D, andexportingthatto SolidWorks.AfterthatI wasable to exportthe file for
sand casting.Afteracquiringthe sandcastedmodel,Iwasable to make a moldof the face.ThenI
precededtocreate a cast usingoomooproducts.
Thirdassignmentrequiredforme tocreate a racing boat.For this,I usedSolidWorkstocreate the parts
of the boat,and laterexportedthe .stl filestothe 3D printer.PLA plasticwasusedand the design
allowedme tofinishinthirdplace. Thisrequiredknowledge about the PLA’sshrinkageinorderto
develop atolerance forthe partsthat were pressure fit.
Figure 12 Printed racing boat
Figure 13 3D model of racing boat parts
9. CustomScale RC Cars
Duringmy free time,Ialsoenjoycustomizing scaledstaticcarsintoRC. I take scale static vehiclesand
incorporate electronicsfromscaledRCcars. Thisincludes microservos,custombattery harnesses,and
LiPo/NiMHbatteries.One example isa1/32 scale plasticmodel carfrom Aoshima.
Figure 14 Aoshima 1/32 takumi 86 model car
The reasonI chose this model wasbecause ithada pre-moldedmotormount,whichmade iteasyto
attach a motor and gearsto run the rear wheel shaft.
Figure 15motor mount with gear contacts
I wentwitha Tamiya4WD dash2 motor due to the size andmoderate rpmand torque.I didn’twantto
go witha highspeed ora hightorque motorinorder to reduce the possibilityof damaging the gears.I
alsoutilizedanESC/Receivercomboboardfroma 1/24 scale microLosi truck and a 3-gram microservo
fromcommon sense RC. The size of these componentswere aperfectfit.
Figure 16 Servo placement Figure 17 ESC/Receiver Board
10. For the batteries,Iwentwithtwosingle cell LiPos.The reasonisbecause the board thatis usedto
control the motor and servorequiresatwocell LiPo.AfterfittingdifferentLiPobatteris,Ifoundoutthat
twosingle cell LiPos requireslessspace comparedtoatwo cell battery,andhave longerruntimesdue
to the 450mAh capacity.I alsohad to make a batteryharnessto run the twobatteriesinseries due to
the required7.4V to run the board.
Figure 18 Battery harness and LIPo batteries
Figure 19 Servo Arm connected to Steering Link
For steering,Ihadto attach a pin to the steering bridge thatcame withthe model car.Thisallowedme
to attach the servoarm to the steeringlink.
Overall,Iwasable to convertone of the smallestscale model carsintoa RC by utilizingwide varietyof
componentsfromdifferentsources. Iwasalsoable to utilize electrical engineeringandmechanical
engineeringconceptsto create somethingthatisnotavailable forpurchase.
