John Chiu is a mechanical engineer seeking a position. His portfolio summarizes several projects from his education experience including developing a low-cost force sensor for his master's thesis. As an undergraduate, he led the design of a robotic fish and worked on a Baja car competition. He has experience in mechanical design, CAD modeling, robotics, and sensor integration.

1. John Chiu, EIT
john.chiu62@gmail.com
+1 585 410 5421
Design Portfolio
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2. Table of Contents
Low Cost Millinewton Force Sensor 3
Senior Design Team P14029: Robotic Fish 6
Robotics Project 9
ASEE Model Design Competition 11
SAE Mini Baja Competition 13
Kiln Cart Transfer System 16
Achievements 18
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3. Low Cost Millinewton Force Sensor
Thesis Student
Fall 2014 – Spring 2016
Part of my masters thesis was the development
of a low cost millinewton force sensor. Based on
a cantilevered strain gauge design and an
Arduino DAQ system, the aim of the project was
to reduce the cost of characterization of ionic
polymer-metal composites (IPMCs). Via
Bluetooth serial communications, the data was
processed in a custom LabVIEW program
(below).
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John Chiu
Mechanical Engineer

4. Low Cost Millinewton Force Sensor
Thesis Student
Fall 2014 – Spring 2016
The microcontroller stack developed was based
off of a ARD-LTC2499 ADC shield. An analog, RC
low-pass filter circuit was made prior to the op-
amp to reduce amplification of noises. The
amplification circuit, based on a Wheatstone
bridge configuration (below), was needed in
order for the ADC to read the signals.
10kΩ
+
-
3.3 V
100Ω
100Ω
+
-
350Ω
350Ω
3.3 V
Strain Gauges
47kΩ
1µF
Lowpass
RC-Filter
Single Supply Op-Amp Circuit
ADC
Arduino
Microcontroller
(Optional)
Bluetooth-Serial
Interface
Computer
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John Chiu
Mechanical Engineer

5. Low Cost Millinewton Force Sensor
Thesis Student
Fall 2014 – Spring 2016
The developed millinewton force sensor system
cost around $200. Alternative systems can range
from $300 to thousands depending what sensor
and DAQs are used. This sensor would allow
greater accessibility to millinewton force
sensing.
Part Number Description Unit Price Qty. Total
SDG-3/350-LY11 Omega Strain Gauges 7.70$ 2 15.40$
8265S JB Weld 6.34$ 1 6.34$
NW-026-72 Nitinol #1 Wire, 0.026" diameter 0.24$ 4 0.97$
BTP-1 Omega Bondable terminal pads 0.57$ 1 0.57$
Sub total 23.28$
n/a Arduino Uno Rev 3 19.95$ 1 19.95$
ARD-LTC2499 24-Bit ADC Arduino Shield 50.00$ 1 50.00$
1833 USB Micro-B Breakout Board 3.21$ 1 3.21$
DEV-07914 Spark Fun ProtoShield Kit 9.95$ 1 9.95$
1609 Adafruit Perma-Proto Half-sized Breadboard PCB 4.50$ 1 4.50$
1uF capacitor 1.50$ 2 3.00$
47kΩ Resistor 0.30$ 2 0.60$
100Ω Resistor 0.30$ 4 1.19$
10KΩ Resistor 0.30$ 2 0.60$
108639 Micro USB Cable 1.5ft w/ ferrite core 3.22$ 1 3.22$
Sub total 96.21$
SQ334 6061-T6511 Aluminum Square stock 2ft 8.08$ 1 8.08$
A311214 6061-T6 Aluminum Angle 2ft 9.72$ 1 9.72$
1010 8020 T-Slotted Extrusion 48" 23.20$ 1 23.20$
3393-25pk 8020 Bolt Assembly (25pk.) 18.10$ 1 18.10$
Acrylic Sheets 11.75" x 11.75" x 0.098" 3.75$ 6 22.50$
Sub total 81.60$
201.10$
Radio Shack
Strain
gauge
DAQSystemTestStand
Total
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John Chiu
Mechanical Engineer
Click here for my full thesis

6. Senior Design Team P14029: Robotic Fish
Mechanical Design Lead
Fall 2013 – Spring 2014
Working on a team of four, the senior design
was to develop a fish around the McKibben
muscle (below). A McKibben muscle is made of a
meshed sleeving with an expandable (rubber)
inner tube. When the inner tube is inflated,
either by air or fluid, the center expands. This
expansion then causes an axial contraction
which is analogous in function to skeletal
muscle.
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Actuated
Non-actuated
John Chiu
Mechanical Engineer
Test rig for the muscles. The machined delrin end caps
was designed with an incorporated line tensioner.

7. Senior Design Team P14029: Robotic Fish
Mechanical Design Lead
Fall 2013 – Spring 2014
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John Chiu
Mechanical Engineer
Designed for easy maintenance, the fish utilized a single thread size for all fasteners. The transparent acrylic waterproof box allowed
us to spot potential leakages and errors without needing to open the enclosure. Utilizing water instead of air allowed the muscles to
gain more rigidity when compared to pressurized air. It also had the added benefit of being able to draw actuation fluid from it’s
surroundings instead of a buoyant storage. Using water instead of common hydraulic fluids eliminates the environmental impact in
cases of actuator leakage. The muscles were mounted in the head segment of the fish instead of the tail to allow the use of larger
muscles, which allows for higher actuational power and travel.
Click here for more information from our project website

8. Senior Design Team P14029: Robotic Fish
Mechanical Design Lead
Fall 2013 – Spring 2014
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John Chiu
Mechanical Engineer
The Robotic Fish project was featured in a local news
paper for a campus-wide event. We submitted the
robotic fish to the 2014 ASME Student Mechanism and
Robot Design Competition in Buffalo, NY and took first
place in the Undergraduate Robot Division.
Click here for the online article

9. Robotics Project
Mechanical Design and CAD Lead
Fall 2013
In robotics class were learned about the
different actuational devices, sensors, and
control algorithms for robotic systems. In
groups of two, we were tasked with creating a
project and an objective to accomplish. We
wanted to explore the interesting movements of
Omni-directional wheels and developed the
Security Bot. The objective was to detect an
object placed randomly in a given space lined by
electrical tape. Then the Security Bot must push
the object out of the outlined space and return
to wait for other “intruders.” We utilized ultra-
sonic ping sensors for object detection and a 4-
way infrared sensor to detect the bounds of the
outlined space. The automation of the Security
Bot was based on an Arduino Uno
microcontroller.
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John Chiu
Mechanical Engineer

10. Robotics Project
Mechanical Design Lead
Fall 2013
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John Chiu
Mechanical Engineer
Omni Wheel Directional Movement
(Video)
Completing the Objective
(Video)

11. ASEE Model Design Competition
Mechanical Design
Spring 2011
The ASEE Model Design Competition is held annually at the ASEE Convention for first and second year undergraduate
students. A different game is developed each year by the ASEE board which seeks to challenge students in a point based
competition. We took 3rd place at the 2011 ASEE Vancouver Convention.
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John Chiu
Mechanical Engineer
The 2010-2011 game as about forestry. A wooden track with a plywood base was the setting for our competition field.
Electrical tape was laid out in a “M” shape to aid in line following robots. Randomly placed red and green dowels were lined up
under each arc. The red dowels represented dead trees for harvesting and the green ones were healthy trees. The objective
was to make it around the track as fast as possible and collect as many red dowels as you can, autonomously. Points are lost
for each green dowel knocked over.

12. ASEE Model Design Competition
Mechanical Design
Spring 2011
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John Chiu
Mechanical Engineer
Exploded View Animation
(Video)
Color Sensor
8 QTR Sensor Array Dowel Collection Tray
Dowel Scoop

13. SAE Mini Baja Competition
CAD Drafting Lead
Fall 2009 – Spring 2011
SAE Mini Baja (now just Baja SAE) is an intercollegiate
competition where teams build off-road vehicles to run in
an 4 hour endurance race. Each team is given a 10-
horsepower Briggs & Stratton Intek Model 19 engine. For
the competition, the finished vehicle goes through a
series of dynamic and static tests to earn points. These
tests includes acceleration, maneuverability, hill
climb/traction, special events, and the endurance run.
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John Chiu
Mechanical Engineer

14. SAE Mini Baja Competition
CAD Drafting Lead
Fall 2009 – Spring 2011
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John Chiu
Mechanical Engineer
The yellow frame was the previous year’s model. The grey model
sought to improve on the previous frame by reducing the overall
footprint, weight, and better ergonomics for the driver. Other
improvements included an increased angle of incident of the front
suspension to better absorb impacts, a planetary gearbox and CVT, and
stronger A-arms to resist deformation.
Solidworks stress analysis were done to ensure that the
suspension bracket would hold up to the assumed forces
and fit within a factor of safety.
The Baja frame with a scale model of a 95th
percentile man to check ergonomics.

15. SAE Mini Baja Competition
CAD Drafting Lead
Fall 2009 – Spring 2011
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John Chiu
Mechanical Engineer
(Left) Old upright for the front next
to the new (right), lighter, CNC
machined upright.
New upright assembly. From left to
right: spline shaft for wheel, pressed
roller bearing, splined spacer, and
left-hand hex nut.
Finished Baja car with the high performance Fox Shock (in blue). The
final design utilized a solid rear axle for better power retention
around corners. Large chevroned rear tires were used to increase
traction in loose dirt and muddy conditions.
Improved upper (right) and lower (left)
A-arms utilized a single curved pipe for
rigidity. Previous year’s A-arms were
welded and showed damage at the
welds from impacts.

16. Kiln Cart Transfer System
Mechanical Design Engineer Coop
Nov. 2012 – Feb. 2013
Victor Insulators makes a variety of ceramic
insulators for the powerlines and has been
around since 1893. Founded by Fred M. Locke,
they are the oldest insulator company in North
America.
16
John Chiu
Mechanical Engineer
As a Mechanical Design Engineer Coop, I was tasked to retrofit a an
old kiln cart transfer system from the 60s for automation. The system
had to made under a low of $10k budget, when compared to other
systems which can cost north of $100k.
Prior to development of an
automated system, it was
procedure to move the kiln
carts by had. This posed a
potential risk since the
insulators can weight up to
150lbs each. After firing up the
ceramic pugs in the kiln with
its compressive glaze coating,
when broken, can be as sharp
as razers. Occasionally the
shelves that the insulators are
placed on in the cart will break
due to frequent heating and
cooling cycles.
Kiln
Transfer Car

17. Kiln Cart Transfer System
Mechanical Design Engineer Coop
Nov. 2012 – Feb. 2013
The final design utilized a sourced custom
built hydraulic piston. At the ends or the
dual-opposed hydraulic cylinders were servo
actuated clevis pins that would rotate into
place when in position.
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John Chiu
Mechanical Engineer
This design was the 5th iteration due to cost restrictions
and the capabilities of the staff to implement the
proposed system. Hydraulic pistons were chosen form of
actuation because the kiln carts could weight up to 2 tons
fully loaded. Since the kiln car transfer system uses
hydraulic gear pump for movement, it was simpler to
utilize the on board hydraulic reservoir. The finalized
system was controlled via limit switches and PLCs
implemented by the staff.

18. Achievements
“Science without engineers are just philosophers.”
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John Chiu
Mechanical Engineer
My team was featured in the citywide school calendar after winning 1st place in the 2006
Finger Lakes FIRST Robotics Competition Regionals.
Having attended a FIRST Robotics team for four years in high school, I
learned early on what it meant to design something. I had a passion for
working with my hands and building robots.
Finished 3rd out of 15 in the 2011 ASEE Model Design Competition in Vancouver,
British Columbia
CSWA certified in Solidworks, Spring 2011
Inducted into the Mechanical
Engineers honors society Pi Tau
Sigma in 2014

19. Thank you for your time and considerations!19
John Chiu
Mechanical Engineer
John Chiu, EIT
john.chiu62@gmail.com
+1 585 410 5421
Design Portfolio