This is a private page I’ve created to provide a few examples of projects I’ve worked on. This includes photos of my professional work at Palmer Manufacturing (2014-2015), Accutek Testing Lab (2011-2014), as well as personal projects at the bottom.
Everything shown below was done independently excluding the Palmer equipment & solar car chassis, which were a team effort.
Relevant Link 1: Michael’s LinkedIn Page
Relevant Link 2: Michael’s Resume
Relevant Link 3: Michael’s Professional References
Accutek Custom Extensometer & Calibrator: Hard to see but those aluminum rectangles in the photo would have cost $10,000 were you to buy them new. They are strain gage based extensometers capable of repeat measurements of .0001″ that I custom designed. The red fixture is used to calibrate it.
Accutek Custom Bearing Testing Machine. Designed to dynamically load aircraft bearings in two directions while spinning them. Assembly used servo hydraulic pistons and servo motors for control.
Accutek Custom Temperature Probe Testing Fixture. The machine is a two axis gantry designed to dip test specimens into two separate temperature controlled baths.
Accutek Custom Test Oven (large). This type of equipment normally retails for big bucks. Designing our own version gave us the capability at a fraction of the cost. (The is the story with much of the Accutek equipment here).
Accutek Custom Test Oven (small). Designed to fit a smaller testing machine.
Accutek Custom Strap Testing Fixture. Designed for gripping and tensile testing toeing straps.
Accutek Custom Hydraulic Wedge Grips. Designed to grip tensile test specimens at high loads without applying a preload to the specimens. This design was based on a set I reverse engineered and shrunk down to suit our needs.
Accutek Custom Sterling Freezer: I took apart a portable sterling freezer and remounted it in a new orientation so that we could run tests at ultra low temperatures without the use of liquid nitrogen (an expensive consumable for long tests).
Accutek Custom High Disp Test Machine: I had a need for a super high displacement test machine but I didn’t have the budget for one. So i retrofitted our drop-testing machine with ball screws and a servo motor.
Accutek Custom Torsion Low Temp Test: Similar to the high displacement machine, this adjustable torsion tester was built by retrofitting various existing equipment.
Accutek Custom Vibration Tester: Designed an adjustable height fixture to suit any size shaker. (I did have some help setting this test up).
Accutek Custom Chain Test Machine: This machine can dynamically test up to 4 roller chains at once. Each chain station has independent load control using a pressure transducer and a pneumatic cylinder.
Accutek Custom 3 Axis Load Cells: Each device contains three custom designed load-cells used for ergonomics testing.
Much of my work at Palmer consisted of managing large out of date inaccurate legacy BOMs and making pseudo technical customizations to them.
Above Right: Palmer Manufacturing Sand Heater: This is a machine used to heat sand. I typically made modifications to basic dimensions to accommodate various heating loads, voltages, and sand volumes.
Above Left: Palmer Manufacturing Sand Mixer: This is a pieced together portable sand mixing assembly based on various pieces of existing designs.
Accutek Medical Device Testing Fixture: For subsidence and expulsion testing on spinal implants. There were many medical device testing machines and fixtures that I worked on at Accutek.
Accutek Custom Servo Fatigue Machine: Adjustable tabletop static & dynamic test machine using a ball screw & servo motor. (Shown as 3D model because I had left before this machine was completely assembled).
Accutek Custom Control Cabinet: Used to control 3 of the ‘Custom Servo Fatigue Machines’. I designed, sourced, ordered, and build this whole cabinet.
Accutek Weird Mechanical Test: This is an example of a custom test fixture used to apply a load in a very specific orientation.
Accutek Custom Pump Testing Fixture. Designed to safety test Semi-truck water pumps under various conditions.
Accutek Custom Clevis: This is an example of my personal pursuit of improvement of a work process. I was slightly obsessed with figuring out how to design a single adjustable clevis that could be used for the majority of tensile tests. I came up with an even better design later you can read about here.
College Solar Car Chassis Senior Design Project: You read a LOT more about that here.
All Projects Below are Hobby Work: The intent behind sharing these here is to show that I am a highly motivated person and a recognized innovator in the areas of 3D printing and electric vehicles. My work has been featured on the front page of big name websites including Instructables.com, HackADay.com, 3Dprint.com, and 3DPrintingIndustry.com.
Above left: I converted a motorcycle to an electric vehicle, then I wrote a set of directions for how others can do it.
Above right: My home built 3D printer, ‘printrbot’.
Above Left: My invention for actively combating house fires. I’ve shared the design as open source.
Above Right: I designed and built a tension/compression test machine so I could run tests on 3D printed objects.
Above: The Bicycle BoosterPack. A near universal kit that gives adult bikes an ultralight portable electric power assist.