Duncan Christie Portfolio 2018

Portfolio and Design Showcase 2018 DUNCAN CHRISTIE Bournemouth University BSc (Hons) Design Engineering Graduate DESIGN ENGINEERElegant Design Solutions to Real World Challenges

TABLE OF CONTENTSInside this portfolio: Parametric Modelling of a Simwise WM4D Geneva Wheel FEA AnalysisIntroduction 3 Electronics Housing Assembly and Efficient PackingRIPSIM Tool 4 Solidworks Plastics3D Printing 6Simulation 7Software Proficiency 8Engineering Drawings 9Programming and Robotics 10 RIPSIM ToolProduction Engineering 12Qualifications 14Contact Information 15

INTRODUCTION Design Engineering, a Broad SpectrumMy name is Duncan Christie, a Design Engineering graduate with a passion forprecision plastic manufacturing, injection moulding and rapid prototypingtechnology. Throughout my time at Bournemouth University and a year inindustry, I've developed skills in :Project ManagementProduct DevelopmentAdvanced Simulation and FEAMechanical and Pure MathematicsMechatronic SystemsElectronics and Circuit DesignProgramming (Primarily C++)CAD on a variety of packages.I enjoy puzzles, problem solving, and finding creative and elegant solutions toreal world challenges. With years of industry experience from before andduring my degree as a 3D Printing Technician, Product Designer, Trainee ProjectEngineer and CAD Technician, I can adapt to meet any type of engineering ordesign role.Please enjoy this showcase of my work and do not hesitate to get in touch!

Design Engineering Graduate Project 2018 RIPSIM TOOLRapid Prototyped Smart Injection Mould Tool SMART MOULD TOOLInspired by my time visiting various toolmakers andproduction companies during my placement year, both inthe UK and China, the RIPSIM Tool is a calibration devicefor the setting and troubleshooting of injection mouldmachines. Using an array of five thermal probes locatedwithin the mould cavity, and four cavity pressure sensorsplaced behind the ejector pins, the RIPSIM Tool collectsdata on injection pressure and temperature after eachshot and stores the information on an attached RaspberryPi powered control box. RAPID TOOLING Designed to be an affordable and enticing product for small to mid sized design companies, the RIPSIM Tool uses an assembly of rapid prototyped ABS mould cores housing a pair of resin cavity inserts, produced on a precision SLA printer. Using rapid prototyped components drastically reduces the cost of manufacture compared to a traditional steel mould tool, as well as lead time, shipping costs and maintenance. It also allows for greater flexibility in plaque design. The unit price for a RIPSIM Tool is £2500, a 40% price markup, and solid investment for any plastics company.

Some polypropylene sample Assembly views of the test rig resin cavity inserts, ABSmouldings produced on the test core and carrier sections and some example TPErig, confirming that 3D printed mouldings.tooling is possible and , with someexperimentation, effective! OPTIMISED TOOL DESIGN BUILT FOR INDUSTRY FULLY TESTEDFully functional mould tool designed to a high Designed to work in conjunction with mould setting An example test rig was produced and used instandard for part quality and finish. experts and mould flow analysis technology. sample production runs with four different polymers.

3D Printing Technician/Enthusiast 2014-Present FDM (Fused Deposition Modelling) SLA (Stereolithography) 3D PRINTING Desktop and Ultra PrecisionExpertise on a wide variety of 3D printers.INSTALLATION MAINTENANCEWell versed in the selection and setup I have experience in the long termof a huge range of 3D printing maintenance of many 3D printers,machines, including but not limited to: from extruder replacement, build tray care, resolving material issues,Makerbot 3D Scanners clearing print head jams, calibratingRepRap Print Pen platforms and motor pulleys.EnvisionTec HPUp!Mini Fortis OPTIMISATIONZortrax FormlabsWanhao Vector I can produce CAD specifically opti- mised for rapid prototyping, working OPERATION with and converting numerous 3D model file formats, and manually editFamiliar with a wide range of gcode and optimise gcode strings and tool-compiling software, both unique to paths.specific printers and generic packages.Able to efficiently adjust print angles,material infill patterns and density,extruder speed and temperature andother key 3D printing variables for thebest possible prints.

FINITE ELEMENT ANALYSIS Statics, Pressure Vessel Design, Fluids, Thermal, FatigueExperience in running various SIMULATIONsimulation types including:Thermal Finite Element Analysis, Mould Flow Analysis, AnimationFrequency/ HarmonicsFatiguePressure Vessel Design Harmonic mode shapes pre and post Pre and post optimisation of a pressure manifold: optimisation of a pressure manifold. Von Mises Stress (MPa), leftMesh Convergence Diagrams to maximise simulation Displacement (mm), rightreliability and accuracy. Simulation of the Aft O-Ring on the SS- Challenger spacecraft that was the cause of the 1986 failure.

Easily transferrable to the CAD package of your choice. SOFTWARE PROFICIENCYExperienced with a variety of software packages.SKILLSTrained in Solidworks to a high level across all PARAMETRIC MODELLINGaspects of the software, including various ad-dons such as: Modelling using the equations manager onSolidworks Plastics (Mould Flow Analysis) Solidworks for algebra based geometry. TheSolidworks Toolbox Geneva Wheel above will automatically updateSolidworks Motion (Animation) to suit 4, 5 or 6 slots.Solidworks Flow Simulation The prototype was constructed using 3DSkills on other packages include: printed ABS and CNC routed aluminium, codedCNC Tool-pathing with NX10 on NX.Autodesk 2D and 3D Sketching and use of theMoldFlow SoftwareKeyshot for advanced photorealistic rendering.Material Property Analysis and Selection onCES Selector.SKETCHING AND MODELLING RENDERING AND PHOTOVIEW ANIMATION AND MOTION STUDY SURFACE MODELLING

SKILLS Drawing standards adherent to BS 8888: 2017● Stack Tolerancing● Shafts and Holes ENGINEERING DRAWINGS● Limits and Fits● Template Formatting Geometric Tolerancing, Bill of Materials● Assembly Drawings● Datum Targeting

Proficient on Arduino, Raspberry Pi, PIC, Python AUTOMATIC TOWER CRANE Arduino Programming Design Engineering ProjectA University project to construct a functional automatic crane to locate and acquire aseries of magnetic ball bearings, and deposit them in a target area, using an electro-magnet.Aspects of this project included the design and creation of the crane system,including servos for horizontal and vertical movement of the crane arm, a slidingmotor trolley pulley system to travel along the strut, writing the machine’sinstructions on the Arduino IDE software, mathematical modelling of the momentsand weights involved, polar coordinate geometry and rigorous testing andexperimentation. ROBOT RACER VEHICLE

Autonomous Mobile Vehicle 5G MAPPING ROBOT Year in Industry at the University of SurreyDuring my placement year working with the ICS (Institute for Commu-nication Studies) at the University of Surrey, I worked as part of ateam designing the “Autonomous Mobile Vehicle”, a LIDAR equippedrobot designed to map and create 3D models of interior spaces ,transmitting the data in real time using cutting edge 5G technology.My role was the construction of a test rig chassis and armoured shellinspired by the ancient trilobite, to be constructed from dense rapidprototyped sections. Ribs and layers of plastic plating were simulatedto protect against impacts and falls, whilst still providing a spaciousinterior for the various sensors and data collecting components inside.Additionally, this placement included carrying out the marketresearch, value proposition, product design specification (for bothsoftware and hardware requirements), 3D modelling, design forassembly/manufacture, construction of scale prototype and test rig,and some programming on the MBED platform, for the trilobiteproject.

Focus on Injection Moulding, Toolmaking and Plastics PRODUCTION ENGINEERING Industrial Experience in the UK and AbroadThe majority of my engineering experience revolves around plastics andmanufacturing, whether that takes the form of injection moulding,tooling, vacuum forming, concepts, CAD, testing, engineering analysisor DFM/DFA. Pictures taken from my most recent excursion to Shenzen, China, Summer 2017. Here I was contacting possible suppliers and auditing toolmakers for quality, size and scale of production. -Plastic Moulders -Toolmakers -Electronics Sourcing -Packaging Suppliers

SKILLS/FEATURES INJECTION MOULDING● Draft and Undercut Analysis Tooling, Moulding and Chinese Liaison● Wall Thickness Uniformity Graduate Project RIPSIM Tool Plaque● Draft Angle Tolerancing Testing -Total Fill Time● Sink Marks Analysis -Temperature at End of Cooling● Mould Machine Operation -Sink Marks Analysis● Machine Setting and Calibration● Injection Time/Fluid Dynamics Calculations● Cooling Rates and Cycle Time Modelling● Supplier Sourcing and Auditing in China● Known Contacts and Previous Suppliers● Back Plate Deflection Calculations● Tool Maintenance● Gating Optimisation and Sprue Design

QUALIFICATIONSFinal Degree Qualification: Expected 2:1BSc (Hons) Design Engineering References: Bournemouth University Professor Mark HadfieldFinal Year Modules Covered: Professor of Design Engineering Advanced Mechanics and Simulation - 2:1 Bournemouth University Management and Commercialisation for Technical Projects - 2:1 Telephone: 01202 965983 Research Based Mechatronics - 2:1 Email: [email protected] Design Engineering Projects - Expected 2:1 Tara Burton2014 SolidSolutions 3D CAD Training Course HR/Personnel Manager PMP Recruitment2016-2017 Year in Industry Sandwich Degree Placement Qualification at Email: [email protected] Institute of Communication Studies, University of Surrey Full CV and more examples of my work available upon request!A Levels:MathematicsFurther MathematicsPhysicsEngineering Extended ProjectAS Level Product Design11 GCSEs A* to A

Contact InformationDuncan ChristieEmail: [email protected]. Telephone: 07593369948LinkedIn: https://www.linkedin.com/in/duncan-christie-757402128/Festival of Design: https://fodt.bournemouth.ac.uk/student? studentWorkId=9d249b10-89a6-43ab-9d00-85090a54cf1d

THANKS FOR READING! [email protected] 07593369948https://www.linkedin.com/in/duncan-christie- 757402128/