Engineering Student Design Portfolio - Josh Langsford
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The document outlines Josh Langsford's engineering design portfolio, including two CNC router projects, a 3D printer upgrade project, and two university group projects involving a model glider and RC drag car. It provides details on the objectives, specifications, manufacturing methods, and performance results for each project showcasing Josh's skills in mechanical design, 3D printing, CFD simulation, and project management.
Engineering Student Design Portfolio - Josh Langsford
- 2. SUMMER 2021 – PRESENT: ALUMINIUM DESKTOP CNC ROUTER OBJECTIVE: To design and manufacture a small-scale CNC router capable of reliably machining aluminium to tolerances of 0.05 mm or better. SPECIFICATIONS: • Mechanical resolution: 0.01 mm • Microstep resolution: 0.0025 mm • Maximum feedrate: 4000 mm/min • Machine Dimensions: 720 x 680 x 620 mm • Working Dimensions: 570 x 470 x 125 mm • Spindle Power: 2.2 kW NOTES: • The system uses hybrid stepper motors which provide positional feedback and guarantee accuracy • Structural elements are waterjet cut from ½ and ¼ inch 6061-T6 plate for rigidity, good machineability and corrosion resistance • Mist coolant is used to reduce heat generation and improve surface finish • Ball screws and linear rails make accurate positioning possible and repeatable • Timing belts and pulleys allow for a gear reduction to increase resolution and torque • The structure has been optimised using FEA to minimise deflections and reduce the excitation of vibration modes under load • Initial prototyping in thin cardboard was done as a tactile test to assess structural rigidity • The project is progressing well and the design phase is nearing completion Total Deflection Due to Critical End Mill Load in Y Direction Total Deflection Due to Critical End Mill Load in X Direction
- 3. OBJECTIVE: To improve the versatility, reliability and user friendliness of a Creality CR-10 Mini 3D Printer in printing engineering plastics SPECIFICATIONS: • Prints: PLA, PETG, Nylon, TPU, Chopped Fibre Reinforced Nylon • Max Printing Speed: 80 mm/s • Measured Repeatability: 0.3 mm (approx.) NOTES: • The primary goal of this project was to help me become familiar with the operation of an FFF 3D printer and get hands on experience with the manufacturing process • The original structure and mechanics of the printer were only slightly modified, but the print head/extruder and electronics were completely replaced • The new electronics were housed in a drawer I added integral to the original structure – this allowed for easy maintenance and did away with the clunky stock control box • A raspberry pi and adjustable camera were also added to control and monitor the printer remotely • All wires and connectors were crimped and soldered from scratch which gave me experience in evaluating connection reliability • The ideal print surface for Nylon was determined to be a thin piece of Bakelite phenolic sheet epoxied to borosilicate glass – this gave a flat and thermally stable surface with excellent adhesion • The filament holder on top of the printer was also designed and 3D printed by me to store filament, along with desiccant, ready for use WINTER 2019 – SUMMER 2020: 3D PRINTER UPGRADE/REBUILD
- 4. OBJECTIVE: To design and manufacture a glider to achieve the best flight distance possible with a given initial acceleration GLIDER NOTES: • I was responsible for designing and manufacturing the system while the other members designed the Simulink model and flight data recorder • CFD simulations on the wings and fuselage were completed to optimise the lift/drag ratio • All aerostructures of the glider were 3D printed in PLA with carbon fibre rods for structural rigidity – this allowed the geometry to be complex and aerodynamic but still be manufactured quickly • As a team we achieved a great flight distance of 43 m and a flight time of 6 seconds UNI GROUP PROJETCS: MODEL GLIDER (WINTER – SPRING 2018) & RC DRAG CAR (WINTER – SPRING 2020) OBJECTIVE: To design and manufacture an RC car to achieve the fastest possible time over a 50 metre drag race RC DRAG CAR NOTES: • I was responsible for designing and manufacturing the drivetrain, front and rear suspension and steering systems • Many key mechanical systems were partially or fully 3D printed using high toughness Carbon Fibre Nylon filament and brass threaded inserts • The CF Nylon 3D printing technique allowed for innovative designs like independent front suspension, rims optimised for low moment of inertia and a compound gear train using 3D printed gears – a first for the competition • We achieved a very good time of 5.2 seconds over 50 m and were top of the class for manufacturing quality