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Engineering Design and Manufacturing Portfolio
13 March 2014
ProCure Proton Therapy Center Internship
The bulk of my portfolio covers the work I performed for Procure Proton Therapy Center (now Cadence Health) over the summers of 2012 and 2013. For the summer of 2012 I was essentially handed a blank canvas to conceptualize, design, and manufacture an Optical Immobilization Device (OID) to aid in the treatment of ocular melanoma. No device currently existed at Procure and my only constraints were that it attach and be movable along the metal band around the treatment chair and move vertically up to 30 cm. I collaborated with physicians, physicists, and therapists, gathering their inputs and offering suggestions to create a workable prototype within the first three weeks. After further input, modifications were made to the prototype and I moved on to production, delivering three devices for use in Chicago and Oklahoma City.
Building off the experience I had gained from the previous year, I was tasked with redesigning the previous model. After discussion with the therapists, physicists, and dosimetrists, I learned that the device was too heavy, sharp on the edges, and the LED didn’t have enough versatility. Using lightweight impact resistant plastics, an Arduino microcontroller, and touchscreen, I was able to reduce the size and weight plus increase functionality. Machining plastic versus metal brought certain challenges as did programming the Arduino, which had to be self-taught. By the end of the summer, the design was a huge success. I sincerely enjoyed applying my talents outside the classroom while enjoying working with a wonderful group of profesionals.
Citing for work done during the summer of 2012. New treatment using this device was taken to the 52nd Annual Particle Therapy Cooperative Group. The images below are from the poster that was displayed at this convention and show the device in use over a patient.
Optical Immobilization Device Designs
- Create a device that can aid in the 3-Dimensional setup and treatment of Ocular Melanoma.
- Provide a multi-positional light source for the patient to focus on during setup and treatment
Figure 1: Summer of 2012 Design Figure 2: Summer of 2013 Design
- Aluminum Housing - 5” x 5” x 2 ” (HxWxD)
- LED powered by a 9 volt battery and controlled by a potentiometer. Power controlled using a toggle switch
- LED light transmitted through a fiber optic cable inside of an acrylic rod
- Power was transmitted to the bottom half using DC barrel plugs
- Manufactured using a Bridgeport Vertical Mill
- UMHW Plastic Housing - 4 ” x 5” x 2 ” (HxWxD)
- LED was powered by a 9 volt battery and was controlled using an Arduino microcontroller. Power was controlled using an LED illuminated push button
- LED light transmitted through a fiber optic cable inside of a Lexan rod
- Power was transmitted to the Arduino board through the use of a DC Barrel plug
- Indexing was added to the LED stick to precisely locate positions
- Interfaced with a color 2.8” LCD Touchscreen
- All-In-One design (no bottom half)
- Manufactured using a Bridgeport Vertical Mill
Figure 3: Top Half of 2012 Model Figure 4: 2013 Model
Design Benefits of 2013 Model
- Significantly reduced weight due to more efficient use of space and lighter material
- Increased capability of LED control
- More ergonomic design
- Impact-resistant plastic housing
- Impact resistant LED stick
- Shock absorbing design to protect the electronic components if dropped
- Indexing was added to both the mount and the LED stick for repeatability
Figure 5: Arduino Pocket Prototype
- Figure 5 Before manufacturing the final design, the concept was tested using high-density foam.
Figure 6: 2013 Model Assembly
- Figure 6 shows the conceptual design of the 2013 model assembled with the ProCure LCD screen, 9 volt battery, and Arduino board mounted to the back of the pocket.
Figure 7: Final Housing Design
- Figure 7 shows the final design for the 2013 model is shown above, made out of impact resistant plastic.
Figure 8: Multiple Angles of Final Design
- Three duplicates were manufactured for setup and treatments in the Chicago and Oklahoma City ProCure locations.
Figure 9: Shock Absorbing Screen Mounts
- Shock-Absorbing screen mounts were then manufactured. These would hold the screen up against the faceplate between rubber pads, providing the necessary cushion in the event of a fall.
Figure 10: Touchscreen Assembly
- Figure 10 shows the touchscreen being held in place with the mounts between the shock- absorbing pads.
Figure 11: Completed 2013 Model
- Figure 11 shows the final assembly of the 2013 model
Figure 12: Comparison between models
- A comparison between the two versions is shown in Figure 12, the 2013 (left) and 2012 (right). The black box on the bottom of the 2012 model was a later addition to accommodate the same functionality as the 2013 model.
Valparaiso University Ball-Plate Control System
- Complete a ball-plate control project that will use a camera to detect the position of a ball and activate driver motors to correct its position.
- The project is to achieve a result as demonstrated in this video:
With the frame and concept already designed by a previous student, I was given the task of finishing the development and manufacturing of the project following his graduation. In this time, I designed motor shafts that would be fixed at both ends; one side connecting to the motor shaft and the other side to the table. To make the table balanced, I devised a weight system that could be adapted to the 1” 80/20 Aluminum frame allowing future models to be balanced precisely. Figure 1 shows the motor mounted to its designated stand with the shaft connected to it. Figure 2 is the final assembly, including the overhead camera, motor stand, and weights balancing the table in a stationary position.
Figure 1: Motor Mounted to Stand with Shaft