dsmbiomedical_robert gibbons

FOR INTERNAL USE ONLY

Orthostructural Coop Experience

Robert Gibbons

FOR INTERNAL USE ONLY

Page 2

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

FOR INTERNAL USE ONLY

Page 3

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

FOR INTERNAL USE ONLY

Page 4

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

FOR INTERNAL USE ONLY

Page 5

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

FOR INTERNAL USE ONLY

Page 6

Alternate Views

FOR INTERNAL USE ONLY

Page 7

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

FOR INTERNAL USE ONLY

Page 8

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

FOR INTERNAL USE ONLY

Page 9

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.

FOR INTERNAL USE ONLY

Page 10

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

FOR INTERNAL USE ONLY

Page 11

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

FOR INTERNAL USE ONLY

Page 12

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

FOR INTERNAL USE ONLY

Page 13

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

FOR INTERNAL USE ONLY

Page 14

Basic Keyence• Never knew automated visual inspection systems existed• Basic measurements

– GK2 – Keyence Spring Plunger Vise– 2.0mm Drill Pin Tips

FOR INTERNAL USE ONLY

Page 15

Keyence Operation

FOR INTERNAL USE ONLY

Page 16

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

FOR INTERNAL USE ONLY

Page 17

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

FOR INTERNAL USE ONLY

Page 18

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

FOR INTERNAL USE ONLY

Page 19

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

FOR INTERNAL USE ONLY

Page 20

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