3D modelling and printing, FEA, CFD and electronics

Draw, analyse, make and build

Here are some examples of things that I've meticulously designed over countless hours. I find the process of drawing these parts quite therapeutic. Adding rounded edges to certain areas not only enhances stress distribution from an engineering perspective but also adds an elegant aesthetic. I pay particular attention to concentric radius corners and how they contrast with square faces. Much of my design inspiration comes from Apple products from the 2000s, which I believe represent the pinnacle of product engineering design. Additionally, because many items I design and manufacture are load-bearing, I perform FEA static and dynamic simulations on the models to ensure their structural integrity and performance under relevant conditions. These designs are primarily for research-grade medical devices and components for bicycles. I also work with electronics, often using Arduino, to integrate functionality and innovation into my designs.

UQ bike rack design competition

I designed this bike rack back when I was studying at UQ. This design was inspired by one of the maths courses, probably with drawing curves using partial differential equations. The curve follows the Fibonacci's spiral and terminates as a UQ emblem. I was blown away when they announced the winners and that they were going to make it a permanent installation around the campus. The bike racks are still there today, most notably at the pool, Chancellor's place and next to a few other buildings. Really nice to leave a lasting, permanent thing for the uni. This is where we gather for cycling training with UQCC in the morning, which I still attend when I'm in Australia.

Also in the UQ Contact magazine

https://bpointelligence.com/ebrochure/uq/study-guide-2015/files/assets/basic-html/page21.html

UQ promotes pedal powerUQ’s bike racks are soon-to-become the most sought after parking spots on campus, thanks to a design competition run through UQ’s Property and Facilities Division (P&F) recently.

Universal Nanopatch applicator

The Nanopatch is a microneedle transdermal research medical device. It delivers therapeutics into the upper skin layers, and can also be used to extract biomarkers from within the skin. I designed this applicator for my PhD with the help of Neil to ensure that it's makeable in the workshop. The most innovative part is the thread on the square inner tube that allows adjustable spring compression (and hence application energy) by twisting the outer barrel. The applicator also accepts different patch sizes with a replaceable patch attach receptacle. The 3D printed parts are sealed in epoxy and the entire device can be disassembled and sterilised by submerging in alcohol.

To use it, simply load the patch onto the patch attach (and you'd have a dozen ready for an experiment). Adjust the spring compression length and load the spring with the loading tool, and lock it in place with the top handle by twisting it 90º. Then, attach the patch to the applicator's bottom like a quarter-turn lock. Twist the top handle again to release the patch.

... and some more details some of the more complex parts. I think I spent too much time on the details, but in the end, it was worth the effort.

Instrumented hip implant

This is the modular implant with Hall effect and motion sensors mounted on a custom PCB. We submitted it for priority date patent application during my postdoc at TU Delft. Polymer features were used as the deformable material to allow measurable changes in displacement with the Hall effect sensor, as well as to seal off fluids from the operating environment. Multiple spacers can be inserted to adjust the head offset. A wireless version can be developed in future; the current wired version is for prototyping and research purposes. The entire device can be placed in an autoclave for sterilisation and can either be produced as disposable or reusable devices.

Finite element analysis

FEA simulation of a reverse unibody Stewart platform was conducted for use in an instrumented hip implant. Strain gauges were attached to the beams to measure micro-deformations when force is applied to the artificial hip joint. In this configuration, the device was able to produce three principal forces and moments with strain gauge temperature compensation. The simulation was instrumental in designing the structure geometry to withstand forces ranging from 0 to 150 N. The software used for this simulation was Siemens Solid Edge.

Bike parts and other small parts

Here are some quick drawings for various other hobby projects. I think they show a wide range of items that I draw and 3D print. They are as follows: a visor for my Indigo 5.01 bike headlight, and an Ultegra 6770 offset bracket for the Focus Izalco - the battery intrudes 25 mm wide tyres on the chain stay. Various squib backplates and an Arduino MKR Zero enclosure.

Apps that I regularly use for 3D modelling, FEA and printing

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