Some of my projects over the years...

Product

Pneumatic module for attaching fine fabric fasteners to socks, clothes, etc.

Contribution

The device in development for fine fabric fasteners, based on the device for regular fasteners, had extremely high failure rates. Through extensive testing and analysis, often using high speed cameras, I was able to identify and eliminate many different failure modes, far exceeding requirements. Past engineers at Avery-Dennison had described attaching fine fasteners to putting a piece of cooked spaghetti up a wild tiger's, umm, butt. OK, so, it wasn't that hard, but it was a challenge.

Product

Buttoneer® tool for quickly attaching buttons.

Contribution

I was project leader and lead engineer at Avery-Dennison on a clean sheet redesign for a 4th generation product. Identifying shortcomings in the previous design was key information to greatly improved reliability and usability in new design. I also created the outer shape in CAD based on sketches from a designer, which was a challenging job.

Product

Augmented reality light saber system.

Contribution

As an employee at Radius, I worked with our team in multiple locations, Disney, and electronics and software developer in China to generate design for initial looks like/works like prototype. Cosmetic requirements drove creative approaches to part split of light saber and assembly approach for headset.

Product

3-Day wearable insulin pump with reusable controller.

Contribution

As a contractor, I worked with CeQur lead engineers to create next generation device and resolve numerous design issues. For one issue, where a tolerance stack-up critical to dose accuracy needed to be reduced, I proposed and developed a combined design and assembly concept that nearly eliminated the variation.

Product

Powerstaxx™, an Excel based associative tolerance analysis program.

Contribution

Created, developed, and marketed Powerstaxx™ to make tolerance analysis easier to do. Like many products, it was initially created to address a specific need when no similar product was found. Initial versions were created while I was an employee but this version, with more focus on beneficial feature and ease of use, was made from scratch while working on my own. Sales were never what I hoped for, but those who bought and used it spoke highly of it. A big challenge is that not enough tolerance analysis is done. This is a product to help improve that situation. Customers include Lilly, Battelle Memorial Institute, and Veranex (Ximedica).

Product

Measure as you pour technology eliminates the need for a measuring cup.

Contribution

Building on work of previous engineers at Perimeter Brand Packaging, I was able to make improvements to accuracy and recovery time. Close analysis led to better understanding of how the technology works and improved performance.

Product

Add a counter to an existing inhaler and modify housing shape.

Contribution

Working for Radius as a contractor, I was lead engineer responsible for creating a detailed tolerance analysis of the counter mechanism. This analysis helped identify changes required to meet requirements that were not being met. Next, working with other engineers, made changes to the housing and cover driven by the addition of the counter.

A quick review of the cover.

Product

An existing injection pen needed to be modified from 30 days use to 14 days use.

Contribution

Because this was a temporary product change for a short term run, minimizing changes was imperative. I was lead engineer at Radius responsible for creating a method to change the capacity of the pen with minimal new parts and implement those changes into an existing assembly process.

Product

Lancing device to get blood sample for glucose testing.

Contribution

This started with a mechanism concept from another firm that was not easy to manufacture. I led Radius's development effort to refine it into an easy to manufacture product. Several parts were eliminated and the assembly was mostly in one direction. I worked closely with Nypro's manufacturing team and was involved in all aspects of initial and final verification. The results of one test, a key to reducing pain, far exceeded requirements.

Product

Create new housing with two different faces.

Contribution

Supporting Nokia’s “face lift plus” program, I was engineering lead at Radius, interfacing regularly with Nokia design and manufacturing team. This including being on site at Nokia for 5 weeks and additional travel to Mexico, Brazil, and Japan.

Product

Dry powder inhaler for insulin and other drugs based on a novel drug molecule design.

Contribution

My involvement at Radius started as team leader on initial program to take an SLA inhaler “engine” and create samples for clinical trial. This successful effort led to three inhaler development programs and many years and several millions of future business. I maintained team leadership on one inhaler but remained key technical and program resource for the other two. After years of pharmaceutical development, this platform eventually led to a product, although not insulin.

Product

A simple solution to the unique requirements of less invasive surgery in the chest.

Contribution

Co-developer of concept and initial prototypes. While not a major innovation, 6 – 9 months after doctors initially rejected the concept, they recognized the intended benefits, triggering its development. Ethicon still sells today, over 30 years later. I was very please to be able to identify the surgeons' even before they did.

Product

A percutaneous catheter introducer developed from a doctor's idea.

Contribution

Working in an Ethicon group tasked with evaluating the feasibility of doctors' ideas, I created the initial prototype, engineered and developed the final design, and interfaced with contract manufacturer until release. The result was this product and my first patent.