https://www.jackblane.com/about daily 0.75 2024-08-28 https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599587900119-48G8XTETPDXA4OLJM7FT/linkedIn+profile+%281%29.jpg About https://www.jackblane.com/work daily 1.0 2023-03-06 https://www.jackblane.com/work/balance monthly 0.5 2020-10-16 https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1598990295615-8LV1OMC97A6DS2FJTVH2/balance+white+background.jpg Work - Roberval https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1598999951045-GZ34ZXCWYZ1N7CSVLUK6/roberval+balance.jpg Work - Roberval https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599000595933-84ICUJY4X37E8OWLO9SD/IMG_5556.JPG Work - Roberval Vertical links cast in Aluminum 356. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599071514862-XW7RVWFBHQZ9NI46Y5M4/P1+IMG_5551.JPG Work - Roberval Mold for casting the bronze base of the scale. Note the radiating air vents and sprue hole in the lower right https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1602865949996-3OTMRJUUSNW5ZBVKUM86/Screen+Shot+2020-10-16+at+9.24.17+AM.png Work - Roberval Final CAD model of our scale assembly. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599000599907-PKTPQV2OUBFCN08DVZOJ/IMG_5558.JPG Work - Roberval Horizontal links cast in Aluminum 356. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599071513653-EUF45JR7X9CDYPF3MLJ8/P3+IMG_5554.JPG Work - Roberval Raw bronze castings of the base with gate, runner, and pouring cup still attached. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1602865949113-X2SSK6WZ3Y8HKBOQS8IQ/Screen+Shot+2020-10-16+at+9.24.29+AM.png Work - Roberval Exploded assembly model highlighting off-the-shelf components for which we designed. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599000734674-RVGXJFI75W3UBYUDWI65/IMG_5559.jpg Work - Roberval The base cast in Everdur Silicon Bronze. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600789382133-H7HBO6QHWGZXPL96C4VK/IMG_7875.jpg Work - Roberval Mold for casting the vertical aluminum links with air vents. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599069517303-K690DVUO5OQUZG4PRJFK/Frame%2B1.jpg Work - Roberval A collection of sketches that I used for generating ideas, exploring design aesthetics, visualizing fabrication processes, and back-of-the-envelope calculations. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599074100652-5QS8TAIAAPYWMS4EXL8A/P4+IMG_5610.JPG Work - Roberval Short shot part defects on the horizontal links. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600789384252-TGEHOWONL10CYTTL0M7R/IMG_6702.jpg Work - Roberval Me pouring aluminum castings with a co-worker (Manu Garzaron). https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599069557852-95ZOITWH5I0SJ0X3YEG1/IMG_5498.JPG Work - Roberval Rapid prototyping with laser cut parts, roller bearings, and small, calibrated "weights." https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599071513646-S32MBHHR3GD6YXABWUL3/P2+IMG_5549.JPG Work - Roberval Molds with weights, fire jackets, and full pouring cups from a recent aluminum pour. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599074100655-2TULX1HKA41YSBUYL1VY/P5+IMG_5609.JPG Work - Roberval Sink defect around the through hole on the horizontal links. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599069596173-F96Z3ZPH48UWRPWILVI7/IMG_5538.JPG Work - Roberval CNC milling the cope and drag side parts of a family pattern board out of UHMW (ultra high molecular weight). https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599074097370-SK7LYGXUQVAG06TO8T5Z/P6+IMG_5580.JPG Work - Roberval Jig for kinematic constraint of bronze base for repeatable, precise CNC post-machining. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600789390656-7YKT2JTGE4ISGISOYAMG/IMG_7973.JPG Work - Roberval Fixture for compliant constraint and repeatable CNC post-machining of the vertical links. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599070140364-LSDGZWR91ICHTYXS9PUM/IMG_20200526_151202.jpg Work - Roberval Two-sided pattern made of CNC routed Modulan, to be cast out of bronze for the dense base of the scale. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599070142319-B7ZPT9KTBJRB7L972S18/IMG_20200526_151129.jpg Work - Roberval One-sided family pattern made of CNC milled HDPE for the four cross links, to be cast out of Aluminum 356. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599070149547-PGNWS70WQPOP2FO4IB4T/IMG_20200526_151609.jpg Work - Roberval Two-sided family pattern made of CNC milled HDPE for the vertical links, to be cast in Aluminum 356. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599074096693-3YL2DK3SGQSRAWJ9IGT3/P7+IMG_5585.JPG Work - Roberval Using a go/no-go plug gauge to measure a bore hole for a bearing press fit. Because of variability in our shop CNCs, we designed these parts with steel safe machining in mind. Progressive machining operations removed material until we reached a hole size of .497"(+.001-.000). https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599074100450-DNVG36EG4XIU6KK3QK0X/P9+IMG_5597.JPG Work - Roberval Manual milling in progress on the bronze base. Note the slots that we designed intentionally for fixturing purposes. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599155952234-QV48QAAKTUB5LJ01DL0W/Frame+3.png Work - Roberval FEA and flow analysis for the horizontal links. https://www.jackblane.com/work/mechanical-systems monthly 0.5 2020-09-30 https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600952513086-AZ94GBJRSBF17Q4TT5W9/IMG_5870.jpeg Work - Prototype Mechanical Systems https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963120524-0KVSTJEWNWVIDAI89PJW/bistable+mechanism+sketch.PNG Work - Prototype Mechanical Systems Early sketches https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963496779-VXDEUH9R835DNRVEBHTH/wheel+interation.jpg Work - Prototype Mechanical Systems Iterative wheel designs. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963124766-DTFQZ9VWO5DDCDX082JO/bistable+mechanism+prototype+0.JPG Work - Prototype Mechanical Systems First mechanism prototype. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963129289-GT397VG3HAXWK8YLJEFZ/bistable+mechanism+prototype+1.jpg Work - Prototype Mechanical Systems Second mechanism prototype. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963120498-4FAVVW3WAE3FETQPBX2K/bistable+final+prototype+unfired.JPG Work - Prototype Mechanical Systems Late stage prototype in unfired position. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963121408-1EBATQ36HI3ZPJK1TK2R/bistable+final+prototype+fired.jpeg Work - Prototype Mechanical Systems Late stage prototype in fired position. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963120936-Y2FCINPW6WB4VWHNECS0/angled+view+of+final+mechanism.jpeg Work - Prototype Mechanical Systems Closeup of final mechanism in the unfired position. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963119362-X6IT1Z4R3T72IWZIBI37/top+down+view+of+final+mechanism.JPG Work - Prototype Mechanical Systems Top down view of final mechanism in unfired position. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963126528-J1C9FU2YE87UR6PKX5V0/bistable+mechanism+closeup.jpeg Work - Prototype Mechanical Systems Closeup of mechanism holding salamander. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963496517-FHR3TUA6VJ7JZVE3OVQO/early+prototype.JPG Work - Prototype Mechanical Systems Late-stage prototype with four-wheel drive and alternate grabbing mechanism. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963495673-5FRV06GRD29IXLYQVT78/another+early+prototype.jpg Work - Prototype Mechanical Systems Mid-stage prototype with functioning rear-wheel drive-train and salamander grabbing mechanism. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963526440-DDLCRK3H5869Q66RX893/IMG_5877.jpg Work - Prototype Mechanical Systems Crawler robot retreating down the tunnel with captured salamander. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600964298761-GVHFILJ7766GP4GMBTQ5/Frame+7.png Work - Prototype Mechanical Systems Left: Unfired mechanism before contacting the wall. Right: Fired mechanism holding the salamander after contacting the wall. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963496674-MXCD4U4KXDB2UM8NK7U8/yet+another+prototype.jpg Work - Prototype Mechanical Systems Early prototype. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963526671-JAIJNTTCRCXXB9CPR6OG/IMG_0330.jpg Work - Prototype Mechanical Systems Top-down view of our 70:1 four-wheel drive lego transmission. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600963524718-AQ1G0QRU7WTI70S8R3XL/IMG_5914.jpg Work - Prototype Mechanical Systems Top-down view showing how four linear guide-wheels directed our robot down the tunnel. https://www.jackblane.com/work/rover monthly 0.5 2020-09-21 https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600455247649-NE00BKZSVER3JL7D1V6E/For+Presentation-06817%281%29.jpg Work - Rover https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600695857901-ZB4UCQ6ZHXBB6K2HZML1/Robot+system+architecture%281%29.jpg Work - Rover https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457378848-L191LO6E9OW61NF14EBL/For+Presentation-03988.jpg Work - Rover Testing and building the robot in the Chavín archaeology lab. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457883787-14XP9BLACSKETVN1FC38/IMG_6207.jpg Work - Rover Me sharing the ceramic bottle with the archaeology team. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457172176-5KBJSLTWF8Z10093H64I/For+Presentation-04849.jpg Work - Rover Building the first version of the robot shortly after arriving in Peru. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457405874-BMOL3QUAMT5C6UT0N7YA/For+Presentation-04838.jpg Work - Rover Wiring the motors to the motor controller. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457882127-QGTQS9V815ZM2YZTF0XJ/IMG_6223.jpg Work - Rover Daniel was able to retrieve the bottle from the tunnel. It was one of the most exciting discoveries of the summer. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457171218-S9YMHDOIT7NC5JQ3553L/For+Presentation-04847.jpg Work - Rover We had access only to tools that we brought ourselves. Fabrication required creativity, repeated trips to tiny hardware stores, and hot glue. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457405989-ROI1Q7CPKFTFVLTIVF4M/For+Presentation-04866.jpg Work - Rover Whiteboard layout of our robot's architecture and wiring. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457881869-DM8593AY9GG0W3P7JTHN/IMG_6220.jpg Work - Rover The 3000-year old, unbroken ceramic bottle from the Chavín culture before cleaning. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457171097-S1OMOSQM5NNS9AQPJX4B/IMG_2321.jpg Work - Rover Daniel Chan testing the first rover build. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457402114-W7CW3CYALP23HK27CMNM/For+Presentation-04870.jpg Work - Rover Daniel and I with v1 of the robot. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457883332-YQKABGXDX70V5ZTMRZV3/IMG_2997.jpg Work - Rover The bottle was likely a sacrificial artifact used by the Chavín in religious ceremony. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457398042-H743PT1XOM2A7H3HYSIA/For+Presentation-04887.jpg Work - Rover Testing v1 of the robot in relatively spacious underground tunnels. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457379919-1HQQR4YYV4YI9LWKJYT6/IMG_2735.jpg Work - Rover Explaining features of the robot to local archaeologists. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457390529-EOWIG4896YU8VTZBBQ2I/For+Presentation-05294.jpg Work - Rover Field fabrication using epoxy. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457396397-8GIL451U2SILR7A99OXQ/For+Presentation-05337.jpg Work - Rover v2 of the robot with larger wheels and a headlamp. Note the broad wheelbase. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457394344-JHQUAANTTRLIGYBGYFHA/For+Presentation-05971.jpg Work - Rover v3 of the robot, note the narrow wheelbase. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457379437-E3WLOCFZGUA68PSMAZV8/For+Presentation-06751.jpg Work - Rover v4 of the robot. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457379426-ZVYVPQ2PWZFZBSWKL35U/For+Presentation-06737.jpg Work - Rover Closeup of v4 with servo mounted distance sensor and camera visible. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457379188-2OZABH5HBPKR66IJY8IB/For+Presentation-06012.jpg Work - Rover At the start of an unexplored tunnel. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457399560-AHCAMXJ6OVH6AXVZGGTD/For+Presentation-05158.jpg Work - Rover Watching our robot disappear down a ~50m tunnel. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457394512-Y6W70DZLEVZ1S4PUQPYU/For+Presentation-05151.jpg Work - Rover Controlling the robot in the field. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600457381328-824Z1R8DOY9VZG9LZJY3/For+Presentation-06817.jpg Work - Rover A narrow tunnel representing the real value of our work. Human exploration of these tunnels can be dangerous or impossible. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600540837154-TV6NYSCV70KL8JK8QLC5/Screen+Shot+2020-09-19+at+2.39.36+PM.png Work - Rover Daniel and I on the site with our robot. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600540871313-106XOYKHJG1LLVITTBTC/Screen+Shot+2020-09-19+at+2.40.04+PM.png Work - Rover Glamour shot of the Chavín rover in the temple complex. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600540838996-UWCTSU05X9J5MNKAIW9U/Screen+Shot+2020-09-19+at+2.39.52+PM.png Work - Rover Using the robot, we discovered a 3000-year-old unbroken ceramic bottle in a narrow tunnel. https://www.jackblane.com/work/sumo monthly 0.5 2020-09-20 https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600451237034-HZ16T73RWVQZTYJGYOJC/WhatsApp+Image+2020-03-13+at+4.04.38+PM.jpeg Work - Sumo https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600285507754-YFDE2JESGSJY2EWPPN7S/Screen+Shot+2020-03-13+at+3.22.28+PM%281%29.png Work - Sumo The gameboard, aka the Pi, on which the competition took place. Robots are placed on the starting mark (red +) and move the walls to try and control as much of the Pi as possible over 2 minutes of gameplay. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600451078504-4PS8QZ25NMBGVAWVV5BF/WhatsApp+Image+2020-03-13+at+3.01.17+PM.jpeg Work - Sumo https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600284775936-GK41QT3NJVZU0EBOP3YX/IMG_20200308_191922.jpg Work - Sumo The team, “Farad’s Phenoms,” on competition day, [left to right] Song Ling Shin | Mechanism Lead (M.S. Computer Science) Jack Lane | Sensor Lead (M.S. Mechanical Engineering) Thomas Kuan | Drive-train Lead (M.S. Mechanical Engineering) Albert Feng | Software Lead (M.S. Computer Science) https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600450698540-FI0XC5ZR239ZSANEOL0O/Screen+Shot+2020-09-16+at+7.12.39+PM.png Work - Sumo SolidWorks model of the lower level of our robot. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600450719983-TCXKZ7F587VP85MTBIMA/Screen+Shot+2020-03-13+at+2.34.24+PM.png Work - Sumo Ki-CAD schematic of the IR sensor circuit that I designed to amplify and filter the gameboard 1kHz IR signal. Click to enlarge. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600450698022-PITTI89F5KKBAVZEEZ5J/Screen+Shot+2020-09-16+at+7.12.27+PM.png Work - Sumo SolidWorks model of the upper level of our robot. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600450719856-U51PZ5FIJV80TQNUSR0V/Screen+Shot+2020-03-13+at+2.45.45+PM.png Work - Sumo Complete Ki-CAD schematic of our robot, showing how the IR sensor circuit fits in to the architecture of our robot. Click to enlarge. https://www.jackblane.com/work/luna monthly 0.5 2020-09-24 https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600005675057-BJO60PWBQOKR3IQTSRLV/Luna+Punch+and+Die.jpg Work - Luna https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600282693405-KOWR4SFXRTP5I755LWH4/IMG_3943.jpg Work - Luna Having fun on a Bridgeport manual mill, prepping stock before CNC milling. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283148616-RJB28ZF0AINVI5C45EW1/IMG_3952.jpg Work - Luna CNC machining the die side of the tool. Marks from facing with a shell mill visible. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283608156-2891N6HWQX7ZAP5036BZ/IMG_4049.jpg Work - Luna Lining up the workpiece with the tool. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283770606-X6TLGHEWGUENPQTG8NJ5/IMG_3999.jpg Work - Luna An example night-light, using a small tea candle, made with punches from Luna. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283173549-0ZEZ0F4ECJDZKNGC19RQ/IMG_3959.JPG Work - Luna Checking fit for the slide bearing to withing .001" using pin gauge. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283607704-6QZH2ABDQHOHV9KSNHFK/IMG_4048.jpg Work - Luna Punching with a small arbor press. Note: this was not a user friendly process due to the pin binding problem explained above. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283772531-68MZ9LSSCIRM9TEQFN60/IMG_4079.jpg Work - Luna Blanks, some of which have been sanded and/or given a hammer-tone pattern with a ball peen hammer. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283153529-W1JYVLTUHSH4O33GQUI7/IMG_3953.jpg Work - Luna Finished die next to square stock for the punch side. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283606543-PJ2N62XKZKBEW022BG4N/IMG_4069.jpg Work - Luna Bending a small night-light enclosure on the box-and-pan brake. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283801121-F73S5GKW1Y3F383G4N1N/IMG_4080.JPG Work - Luna Two other night-light prototypes, made using Luna and manual sheet metal tools. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283154227-KOYAHSIEH4VXFMXJ72XS/IMG_3962.jpg Work - Luna Finished punch and die with parallels for manual machining. Note the tabs for tool separation on the punch side. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283147602-K8ENZM69SC682PEW7PLX/IMG_3972.jpg Work - Luna Reaming the slide bearing holes on a manual mill. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1600283154224-EU3T35FN28G77ZLIQG8X/IMG_3997.jpg Work - Luna Completed punch and die with test pieces. The quality was remarkably good – Luna made punches and blanks clean edges and no need for de-burring. https://www.jackblane.com/work/bracket-challenge monthly 0.5 2020-09-15 https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599163099042-W5Z5GO512IKD3I4M4U4A/bracket+white+background.jpg Work - Bracket Challenge The final brackets. The brighter left-hand bracket is untreated while darker right-hand bracket received a T6 precipitation heat treatment. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599169730420-2V7FL7MTSFRU707H6SLC/IMG_5345.JPG Work - Bracket Challenge Holding a recently poured aluminum casting. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599261895054-OWD988J8H59W69YNJLER/bracket+topology+process.PNG Work - Bracket Challenge A progression of topology optimizations in Solidworks. We used this design tool to maximize the stength/weight ratio of our bracket while reducing the weight to less than 0.2lbs. Afterwards we used the Design Study tools in Solidworks to refine the rib thicknesses to further maximize strength/weight ratio on the rightmost design. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599264340253-W7N22P13JXNHQAYYAY1I/Frame+5.png Work - Bracket Challenge FEA in Solidworks showing a factor of safety of 5 for the yield strength of our bracket after a T6 heat treatment. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599266030423-5BULC2NZ468SASD8DN4M/IMG_5396.jpg Work - Bracket Challenge Manual machining the cast brackets in order to remove parting line and draft for flat mounting. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599264340190-D6NH9MV7E1UFKGSBHFTP/Frame+6.png Work - Bracket Challenge Maximum deflection of the bracket with 100lbs was expected to be around 2mm. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599266033964-LL92CD0SLP82Y1M9SAAN/IMG_5402.jpg Work - Bracket Challenge Quenching the bracket during the heat treatment process. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599264103859-3CFQ1QPR0UB0GRSCLFO5/IMG_5290.jpg Work - Bracket Challenge CNC machining the pattern out of UHMW. Fixturing accomplished with brass screws holding the stock to an acrylic plate. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599266033450-FXZJF6F74E1Q3SGNOQYO/IMG_5434.jpg Work - Bracket Challenge Testing our bracket with ingots as weight. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599264098046-GZD8WIWGUHC1TJT65R2S/IMG_5318.jpg Work - Bracket Challenge The two-sided pattern affixed to the pattern-board with dowel pins for alignment (before applying shellac). https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599266034567-0N4DMSQKX0DZC55JXQH9/IMG_5440.jpg Work - Bracket Challenge Testing was done in the PRL courtyard. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599264120492-H5HFJHXLBTHRC09HZH1B/IMG_20200526_151648.jpg Work - Bracket Challenge The finished pattern-board with shellac. The drag side of the pattern with gate and runner is visible. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599266036122-9OC76FC9LBHZUIRUPE1I/IMG_7745.jpg Work - Bracket Challenge Other bracket designs lined up on test day. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599264105205-OJE8JTK15M51HGOF4TFH/IMG_5335.jpg Work - Bracket Challenge Finished sand mold with pattern in the foundry. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599266034367-XDM5YAKUWKNCK6K8ZPHC/IMG_5345.jpg Work - Bracket Challenge Me holding a recently cast bracket. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599264120778-C09UKCPE8RZLB3LVYYNE/IMG_5359.jpg Work - Bracket Challenge Close up of a clean pull of the pattern out of the sand. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599264107834-2BJK1TOX1H4M9J3PHIZD/IMG_5367.jpg Work - Bracket Challenge Aluminum castings. Some parts suffered from misalignment due to the hand-work nature of our foundry. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599264116889-ACTVFNQHJSU8TI57LLV8/IMG_5394.jpg Work - Bracket Challenge Tools, soft jaws, and engineering drawing for manual machining. https://www.jackblane.com/work/banana monthly 0.5 2020-09-09 https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599693957047-DRRPV73OQAOT4R9JWNL6/banana+hammock.png Work - Banana Hammock https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599693937956-MUP3W3BFHM4U01746MN0/Screenshot+%2823%29.png Work - Banana Hammock https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599693739632-HRGIWWNAQ0K7NLEYS1TG/Screenshot+%2824%29.png Work - Banana Hammock https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599693737587-PV3NMJ2I0LNYWTDHLA5L/Screenshot+%2825%29.png Work - Banana Hammock https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599693739406-2F9CXYR1Z5AMU40LRU4G/Screenshot+%2826%29.png Work - Banana Hammock https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599693739033-RFJTRZ97J4Y1CLWLY1V0/Screenshot+%2827%29.png Work - Banana Hammock https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599693738679-N4F61MH6XAQNHZEYALLB/Screenshot+%2828%29.png Work - Banana Hammock https://www.jackblane.com/work/precision-laser-mount monthly 0.5 2020-09-08 https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599602193627-L72LL3I9HKEMD4E9K8YE/00100lrPORTRAIT_00100_BURST20200521172046216_COVER+%281%29.jpg Work - Precision Laser Mount https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599605498905-1DHSWCMAFZMCTBEAOQA3/Screenshot+%282%29.png Work - Precision Laser Mount https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599605507396-6CIIERESI7VKO043HYA9/Screenshot+%283%29.png Work - Precision Laser Mount https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599605512725-RSEQXANQPCLRN2TBKENE/Screenshot+%284%29.png Work - Precision Laser Mount https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599605508133-KTYWGWBP2V9SNQDMUA7D/Screenshot+%285%29.png Work - Precision Laser Mount https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599605505223-495UO3ETJ0R39ZSN8GKT/Screenshot+%286%29.png Work - Precision Laser Mount https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599605514382-01HW9YKPLM6BG3OY281J/Screenshot+%287%29.png Work - Precision Laser Mount https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599605510943-GTQM9W4AUF859COTWX24/Screenshot+%288%29.png Work - Precision Laser Mount https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599605509502-ZBNQS0R84VG4HRGHD29X/Screenshot+%289%29.png Work - Precision Laser Mount https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599605514093-3T6MD4VTDB3E5B19EN4Q/Screenshot+%2810%29.png Work - Precision Laser Mount https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599605515615-UV02CV55067CFP2OAUEL/Screenshot+%2811%29.png Work - Precision Laser Mount https://www.jackblane.com/work/dogwood monthly 0.5 2020-09-08 https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599348014459-QGJ1PZZH7MNECWMBAIQ5/Hero+Shot+%281+of+6%29.jpg Work - Dogwood https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599589754683-NDWUN4MYY96D6XMRXEVB/IMG_5004.jpeg Work - Dogwood https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591087065-YVJ28HQV5PRLLK1GDDDH/IMG_4605.jpg Work - Dogwood Reflecting on the prototype successes and failures. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591261622-B8SFMJM91R9RN3JO2S4R/IMG_4638.jpg Work - Dogwood Using a power ring roller to bend square steel tubing. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599590885578-ENO4LDDOFQKQ1D4GIS35/IMG_4583.jpg Work - Dogwood Initial idea and personal meaning for Dogwood Wagon. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591086494-CN0DTV7W7WW1Q2DTMXU7/IMG_4629.jpg Work - Dogwood Sketching to think about fasteners and connections. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591259112-1VGT0PM3OBQGMDAY7B0S/IMG_4643.jpg Work - Dogwood Tack weld from a practice welding session. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599590882221-SSYKIXFMW0P9VW5F6TJ3/IMG_4584.jpg Work - Dogwood Early explorations of aesthetic. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591686962-WWIY8XE2N4CJSEF15WZG/Dogwood+Fasterner+Detail+%281+of+3%29.jpg Work - Dogwood https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591099567-I3EOS1MDQ26Y9TD3YWFA/IMG_4676.jpg Work - Dogwood Simple manufacturing operations sequence to help myself approach unfamiliar processes. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591261837-XK4IWMIYI9AJ11N8M3TW/IMG_4654.jpg Work - Dogwood Practice welds showing the variability of my early welds. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599590889993-BBXGWGTLF4W1YBDWQJ5N/IMG_1810.jpg Work - Dogwood Functional prototype, testing the two-wheeled design. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591687249-94WHNR1X9FJ7RVROEWQG/Dogwood+Fasterner+Detail+%282+of+3%29.jpg Work - Dogwood https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591259701-4WRRR9P5BGGWVGRUCSAV/IMG_4703.jpg Work - Dogwood Laying out tubing on a large, 1:1 engineering drawing. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591687127-IFGDJN8A4RKYVD8KGUB0/Dogwood+Fasterner+Detail+%283+of+3%29.jpg Work - Dogwood https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591309641-OABCS8E44DZJKTUWXR4M/IMG_4809.jpg Work - Dogwood I spent a lot of time welding with the frame in unusual positions. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591692532-FTCLKU9IJPZBYEDETWP3/IMG_5277.JPG Work - Dogwood https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591258491-NQ8AYE7PK6Y8P8REUCFO/IMG_4728.jpg Work - Dogwood Quality of the welds improved significantly from my early attempts. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591300068-9IU27WXNIYBMH1Z6OYZY/IMG_4729.jpg Work - Dogwood Testing the axle, bearings, and shaft collar connections on the unfinished frame. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591312467-YJL537RLOZCYENN4STG1/IMG_4738.jpg Work - Dogwood Cold setting the frame to the proper geometry. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591310255-NKW9Y9GPHS4M5LS9QOPO/IMG_4806.jpg Work - Dogwood Getting ready to attach the back legs. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591307324-R3HHUECBB8KOMHG3MNBM/IMG_5001.jpg Work - Dogwood Final welds at a crucial joint. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591303943-G0SB7CB5Y0ZNAMST841U/IMG_5004.jpeg Work - Dogwood My welding comfort and skill improved tremendously over the course of this project. https://images.squarespace-cdn.com/content/v1/5f497ed8aa5c932208b46372/1599591315238-DCKIAHROROXE8B4Z6S3G/IMG_5026.jpg Work - Dogwood The finished frame sitting on the welding table.