1. FOR INTERNAL USE ONLY
Orthostructural Coop Experience
Robert Gibbons

2. FOR INTERNAL USE ONLY
Page 1
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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Page 2
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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Page 3
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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Page 4
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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Page 5
Alternate Views

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Page 6
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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Page 7
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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Page 8
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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Page 9
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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Page 10
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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Page 11
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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Page 12
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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Page 13
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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Page 14
Keyence Operation

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Page 15
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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Page 16
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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Page 17
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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Page 19
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