FOR INTERNAL USE ONLY Orthostructural Coop Experience Robert Gibbons
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Orthostructural Coop Experience
Robert Gibbons
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Expectations• Designing Experience
– Completing real world designing projects
• Exposure in the Bio-medical Field– Discovering what a Mechanical Engineer can contribute
• Manufacturing Experience– Observing real world manufacturing practices
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Designing Background• Drexel’s Classes
– Most recent class on Creo 2.0 was still very basic– Was useful for learning how to create models based off
drawings– Don’t teach how feasible a part is to manufacture– Don’t spend much time on GD&T terms
• Other 3D Modeling Software– Exclusively use Solidworks in my Formula SAE club at Drexel– Used Siemens NX 9 at my last CO-OP with Southco
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Screw Inspection Blocks
• Goal– Hold screws level on the
Keyence to inspect key features
• Result– Designed a fixture that
proved to be unsuccessful with metal screws, but could work for plastic screws
• Learned– How construction lines can be
helpful in the designing process
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Starrett Angle Fixture• Goal
– View each screw’s helix angle– Easy to manufacture
• Result– Created a fixture that served
its function and proved versatile enough to act as a tabletop for other parts
• Learned– How to display different
scenarios in one assembly model
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Alternate Views
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Keyence Screw Rotation Pins
• Goal– Rotate screws on Keyence’s vise
while accommodating for screws with different drive features
• Result– Rotation pins which rotate screws
without slop – Replaceable tip feature which can
accommodate for new drive features in the future
• Learned– How to use modify an existing
fixture to preform in a new manner
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Other Designing Projects
• Bone Plate– Accurately modeled a customer’s fully contoured
product based off of their 2D drawing– Used this model to create a DXF file to inspect our
prototype
• Plate Blanks– Created models and drawings for a family of
plates which eventually will be used to make the Bone Plates
– Modeled an existing machining pallet in Creo to be used in a tool drawing using a 2D drawing and visual inspection tools
• Indicator tips– Created tips with rounded blades to measure the
depth of screws with slotted drive features
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Bio-Medical Field Exposure
• I already have experience with companies that were common workplaces for Mechanical Engineers, I wanted a different experience
• I quickly discovered the Bio-Medical field holds its self to a much higher standard than any other industry, typical tolerances to +/- .05mm or less.
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Bio-Medical Field Exposure
• Machinery and overall capability of DSM to manufacture parts in house truly impressed me– Other industries I worked in always dealt with sending
their products over seas to be manufactured, and suffered through poor quality
• First time in a cleanroom• Manual inspection of each part produced
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Bio-Medical Manufacturing
• Got to see the differences between machining plastic and metal
• Was a part of multiple polymer extrusions• Helped write documents which dictate the manufacturing
process– Routers – QA Procedures – IHR– DSS– Machining Systems
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Manufacturing• I have only had real exposure to
manufacturing one-off parts, but here I was able to see and understand all of the background, set up, and fine tuning it takes to produce many parts in tight tolerance
• Still find it amazing how quickly parts can be produced on CNC machinery
• Was exposed to wire EDM, water jetting, 5 axis CNC mills, Swiss lathes, metal part de-burring processes, and other machines and processes which are used to make a final part
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General Mfg. Support Tasks
• Preformed tasks including,– Weekly inventory update and bi-weekly TPT forecast
update– Analyzed labor reports– Request Tool, QA, and Part numbers– Placed Oracle requisitions for part orders
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Basic Keyence• Never knew automated visual inspection systems existed• Basic measurements
– GK2 – Keyence Spring Plunger Vise– 2.0mm Drill Pin Tips
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Keyence Operation
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Keyence Programs• 2.7mm Trim-it Screw
– Created a program to significantly cut down on measurement time
• Cortex and Cancellous Screws– Helped design programs used
to measure key features including
• Major/Minor Diameter• Tip Radius & Angle• Overall Length
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Keyence & Starrett DXF Files
• Keyence– Imported DXF files from Creo
to measure screw thread and head profiles
– Head profiles would be placed into an automated program
• Starrett– Imported DXF files from Creo
to measure screw thread and drive feature profiles
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What I’ve Gained• Creo
– Real world experience – Bettered my drawing skills– New ways to 3D modeling
• Bio-Medical Field – High quality control standards– Very structured processes
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What I’ve Gained• Manufacturing
– Holding tight tolerances over a run– Extruding and pressing polymer– Discovered the capabilities of many different
machines and tools• Keyence
– Experience with a powerful measurement tool– The importance of proper light and focus level– Gained insight to the next generation of part
inspection
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Conclusion• Enjoyed my time here • Could see myself working in the Bio-Medical field
when I graduate• Learned a lot during my time here• Confirms my desire to use 3D modeling software