Welcome to My Projects

Here is a carefully selected list of projects that exemplify my passion for mechanical design and engineering. Each project demonstrates my dedication to innovation, learning, and problem-solving. From designing intricate components and systems to streamlining manufacturing processes, these projects showcase the practical application of my technical expertise and creativity. I invite you to explore the variety of challenges I've addressed and the solutions I've engineered, all of which have shaped my growth as a mechanical engineer.

If you are looking for my portfolio instead, click the button below.

My Portfolio

Capstone Project (In-Progress)

Adaptive Topology Surface Optimization to Reduce Skin Friction Drag for Attached Flow Conditions

More coming soon. Its looking good though! - updated August 2024

NOVEL TURBO IMPELLER DESIGN

COMING SOON, currently busy with my final year capstone project. More updates coming soon but here are a few details for this project.

Flow Rate Optimization
- Aim: Achieve a flow rate of 1,700 cubic meters per hour (m³/h) at peak efficiency.
- Testing: Use an anemometer to measure the airflow rate at the impeller's outlet. Adjust the design to ensure the impeller consistently reaches or exceeds this target flow rate under various operating conditions.
1. Static Pressure Generation
  - Aim: Generate a static pressure of 370 Pascals (Pa) at the maximum flow rate.
  - Testing: Measure the static pressure using a pressure transducer or manometer at the impeller's outlet. The aim is to achieve this static pressure while maintaining the target flow rate.
2. Efficiency Rating
  - Aim: Achieve an impeller efficiency of 85% or higher.
  - Testing: Calculate the impeller efficiency by measuring the power input versus the aerodynamic power output. Efficiency is calculated using the formula: Efficiency(%)=(Power OutputPower Input)×100\text{Efficiency} (\%) = \left( \frac{\text{Power Output}}{\text{Power Input}} \right) \times 100Efficiency(%)=(Power InputPower Output)×100
3. Operating Speed
  - Aim: Operate effectively at a rotational speed of 20,000 revolutions per minute (RPM).
  - Testing: Measure the rotational speed of the impeller using a tachometer. Ensure the impeller performs optimally at this speed and does not exhibit excessive vibration or noise.
4. Pressure Ratio
  - Aim: Achieve a pressure ratio of 2.0.
  - Testing: Measure the total pressure at the inlet and outlet of the impeller. The pressure ratio is calculated as: Pressure Ratio=Outlet PressureInlet Pressure\text{Pressure Ratio} = \frac{\text{Outlet Pressure}}{\text{Inlet Pressure}}Pressure Ratio=Inlet PressureOutlet Pressure Aim to reach a pressure ratio of 2.0, indicating a doubling of pressure across the impeller.
5. Air Velocity
  - Aim: Achieve an air velocity of 50 meters per second (m/s) at the impeller outlet.
  - Testing: Use an anemometer to measure the air velocity at the impeller's discharge point. Ensure the velocity matches or exceeds the target value while maintaining other performance metrics.ext goes here
Supporting Advanced Applications
- Motivation: Develop an impeller capable of handling high flow rates and pressures to support advanced applications, such as high-performance cooling systems or aerospace propulsion.
- Impact: Meeting the demands of cutting-edge technologies and industries requires advanced components that can operate reliably under extreme conditions.

THE UNIMELB ROVER TEAM (URT)

I joined the UNIMELB ROVER TEAM in 2021 as a Chassis Team member with limited initial responsibilities. Fast forward to 2024 and I am the team’s acting Project Lead and Engineering Manager. In addition, I have attended and actively participated in representing URT in the Australian Rover Challenge (ARCh) since 2022, and have achieved 2nd and 3rd place in 2022 and 2023 respectively.

During my time with URT, I've taken on numerous projects, both technical and general, but here are the primary skills I’ve honed

CAD Design - SolidWorks and Onshape
CAE Simulations - SolidWorks and ANSYS Mechanical
Engineering Drawings and Drafting Standards - AS1100
Geometric Dimensioning and Tolerancing (GD&T)
Design for Manufacturing and Assembly (DMFA)
Machining and Hands-on Fabrication
Project Management - General Timelines, Milestones, Resource Allocation and Quality Standards ISO9000
Systems Engineering - Project Timelines, BOMs, Integration

URT 2023

Chassis Team Lead

URT 2022

Chassis Team Member

URT Chassis and Robotic Arm Integration | 2022 to 2024 (Left to Right)

URT 2024

Project Lead: Engineering Manager

KEY PROJECTS - URT

ENGINEERING MANAGER & PROJECT LEAD

URT 2024: Engineering Manager and Project Lead

LUNAR ROVER CHASSIS AND INTEGRATION

URT 2024: Integrated Chassis Assembly

I led the mechanical redesign and integration of the rover chassis, enhancing the 2022 model to create a 20% lighter and more structurally robust design. My work enabled successful developments of the 2023 and 2024 chassis, both of which performed exceptionally well in competitions. Additionally, I significantly reduced maintenance efforts during competitions and accelerated the completion of several sub-systems by two months.

- Achievement: Developed a high-performance and inexpensive complex wheel design with excellent traction on fine sand, featuring rigid spokes and a flexible tread that effectively expelled sand due to its airless design. The wheel exhibited outstanding durability during the competition. I also adapted a high-fidelity non-linear FEA model for rapid prototyping using TPU material.
- How I Achieved It: Optimised the wheel’s design through extensive research, testing for traction and durability on fine sand with 3D Printing. Utilised SolidWorks FEA to ensure the rigidity of the spokes and the desired surface patch of the flexible tread. Leveraged an existing high-fidelity non-linear FEA model for rapid prototyping, refining the design through collaboration and iterative testing.
- Measures of Success: The wheel provided superior traction and durability, effectively managing fine sand and preventing buildup. It allowed the rover to navigate extreme terrain obstacles without maintenance and was cost-effective to manufacture, benefiting from 3D printing.
- CAD Design and Assembly: Proficient in using SolidWorks for advanced and mechanical assembly mates.
- Sheet Metal Design: Experienced in SolidWorks for sheet metal design and tolerancing.
- Engineering Drawings: Skilled in creating detailed engineering drawings and drafting with SolidWorks.
- Finite Element Analysis (FEA): Conducted static, motion, topology, and vibrational studies.
- 3D Printing: Designed and produced custom fixtures, mounts, and quick-swap latches.
- Design for Manufacturing and Assembly (DFMA): Applied principles to optimise designs for manufacturing and assembly.
- Rapid Prototyping and Fabrication: Experienced in rapid prototyping, hands-on fabrication, and machining.
- Integration Planning and Coordination: Developed and managed plans for integrating various subsystems and components.
- BOM Management: Oversaw the creation and maintenance of Bills of Materials (BOMs) to ensure accurate parts management.
- Project Scheduling: Managed project timelines and ensured milestones were met on schedule.
- Knowledge Transfer: Facilitated knowledge sharing and training sessions to improve team skills and project understanding.

3D PRINTED AIRLESS SANDTRACK WHEEL

URT 2024: Airless Sandtrack Wheel

I led the design and manufacturing of airless sandtrack wheels for the 2024 rover, leveraging my previous experience. The goal was to enhance wheel deformability for better surface contact with loose sand, preventing the rover from getting beached. By utilising 3D printing, we achieved the complex geometries needed at a low cost, significantly improving traction and the rover's ability to navigate irregular terrain, which contributed to our success in competition.

- Advance CAD Design: Utilised advanced surfacing techniques and complex lofts, sweeps and boundary features in SolidWorks to create intricate wheel designs.
- FEA Application: Applied assembly contact parameters for linear dynamics testing on ANSYS to ensure structural integrity and performance.
- Material Choice Optimization: Tested various materials, selecting shore hardness 95A TPU for its optimal balance of flexibility and durability.
- Prototyping Techniques: Acquired hands-on experience in rapid prototyping and 3D printing, focusing on custom wheel designs and refining manufacturing processes.
- Design for Performance: Enhanced design approaches to maximise wheel performance on challenging terrains, integrating real-world testing feedback into the development process.
- Design Communication: Physical prototypes provide tangible models that enhance communication among team members and stakeholders, improving feedback and decision-making.
- Testing and Evaluation: Early prototypes allow for rigorous testing and evaluation of form, fit, and function, ensuring that designs meet requirements.
- Documentation and Learning: Each prototyping phase generates valuable data and documentation, contributing to a deeper understanding of design processes and improving future iterations.

DOUBLE LAMBDA ROCKER-BOGIE SUSPENSION

URT 2024: Double Lambda Rocker Bogie Suspension

As the Chassis Team Lead, I spearheaded the enhancements to the 2024 suspension design, drawing from my experience with the 2023 model. The goal was to develop a dynamically articulating, terrain-conforming suspension that delivered exceptional stability and manoeuvrability. We achieved highly successful deployments with the 2023 and 2024 rover suspensions, which both performed outstandingly in competitions. These advancements not only improved performance but also set a new benchmark for future designs.

- Achievements: I designed a lightweight, dynamically articulating suspension system that contributed to a 3rd place finish in the Australian Rover Challenge. This system improved the rover's stability and traction on rough terrain, and reduced vibrations for smoother operation across diverse terrain.
- How I achieved it: Utilising SolidWorks, I modelled 8-bar linkages and optimised the suspension system configuration through Motion Studies and Finite Element Analysis (FEA). I conducted prototype physical testing to ensure that suspension singularity was highly improbable. Continuous collaboration with machinists was especially vital to ensure accurate translation of designs into physical components.
- Measures of Success: The rover's outstanding performance in the competition was a key success indicator. I effectively resolved singularity issues and reduced vibrations, which improved the load-bearing capacity of the chassis. The rover dynamically cleared all obstacles during the competition and won the casual tug-of-war event after the official competition.
1. CAD Design and Advanced/Mechanical Assembly Mates: SolidWorks
2. Sheet Metal Design and Tolerancing: SolidWorks
3. Weldments Design: SolidWorks
4. Engineering Drawings and Drafting: SolidWorks
5. Finite Element Analysis (FEA): Motion and Topology Studies
6. Design for Manufacturing and Assembly (DFMA)
7. Rapid Prototyping, Hands-on Fabrication and Machining
- Design Validation: Conducted design reviews and validation to ensure alignment with project requirements and standards.
- Technical Documentation: Created and maintained detailed technical documentation and project reports.
- Engineer-Machinist Liaison: Facilitated effective communication between engineers and machinists to ensure precise execution of designs.

In 2024, I served as the Engineering Manager, Project Lead, Procurement Officer, and Systems Engineer for the UniMelb Rover Team. I led the development and integration of all rover subsystems, managed procurement to optimise costs and lead times, and ensured seamless system integration. My leadership facilitated the successful deployment of innovative designs and streamlined operations, significantly contributing to the team’s performance in competitions.

- Achievement: As Engineering Manager, I implemented AS1100 drawing standards and adopted ISO9000 principles, enhancing quality and efficiency in engineering processes. I also secured in-kind sponsors, eliminating out-of-pocket 3D printing and additional ANSYS costs.
- How I Achieved It: I implemented AS1100 and ISO 9000 by conducting teamwide training and streamlining documentation processes to meet high standards. I also leveraged industry connnections to get in contact with sponsors for 3D printing and ANSYS.
- Measures of Success: We experienced significantly fewer recalls and drawing review sessions with our in-house machinist. Additionally, there was a noticeable increase in 3D printer ownership and a stronger culture of rapid prototyping, enabling us to meet project deadlines more effectively.
1. - Design Standards and Quality Management: Applied AS1100 and ISO 9000 for enhanced design accuracy and efficiency.
  - Risk Management: Identified and mitigated risks to streamline project timelines.
  - Procurement and Supply Chain Management: Managed procurement processes and supply chain logistics to optimise lead times.
  - Subsystem Integration and Systems Engineering: Integrated subsystems and applied systems engineering principles.
  - Resource Management: Oversaw a budget of 65,000 AUD, ensuring effective resource allocation.
1. Team Leadership: Enhanced ability to lead and coordinate cross-functional teams.
2. Project Management: Developed skills in managing project timelines and deliverables effectively in Microsoft Projects.
3. Communication and Documentation: Improved proficiency in documenting processes and communicating technical information clearly.
4. Stakeholder Management: Improved ability to engage with and manage expectations of various stakeholders.

URT 2024 Double Lamdba Rocker-Bogie Suspension

URT 2023 Double Lamdba Rocker-Bogie Suspension

URT 2024 Chassis Construction w. Modular Mounting

URT 2023 Chassis Construction w. Modular Mounting

URT 2024 3D-Printed Airless Sandtrack Wheel

URT 2023 3D-Printed Airless Sandtrack Wheel

AEROSPACE ROCKETRY ENGINEERING SOCIETY (ARES)

I joined the Aerospace Rocketry Engineering Society (ARES) in 2022, bringing with me a strong reputation in mechanical engineering developed through my work with the UniMelb Rover Team (URT). My expertise in Finite Element Analysis (FEA) was crucial for conducting studies and optimising rocket bulkheads to endure extreme launch conditions. I also contributed to the design of reusable moulds, enhancing production efficiency and cost-effectiveness. My background in theoretical fluid dynamics, particularly in supersonic motion, provided valuable insights for designing rocket systems. These contributions played a key role in the successful development and deployment of our rocket, which was showcased at Spaceport 2023 in America, demonstrating our engineering advancements on an international stage.

During my time with ARES, I've had a few projects under my belt, but here are the primary skills I’ve honed

CAD Design - SolidWorks and Onshape
CAE Simulations - SolidWorks and ANSYS Mechanical
Mould Design - SolidWorks Mould Tools and SolidWorks Plastics
Theoretical Supersonic Fluid Dynamics: Ackeret’s Theory/Approximation
Design for Manufacturing and Assembly (DMFA)
Carbon Fiber and Fiber Glass Handling
Machining and Hands-on Fabrication

SpacePort 2023 - Project DEIMOS (ARES)

KEY PROJECTS - ARES

PROJECT DEIMOS: NOSE CONE MOULD

ARES 2023: Project DEIMOS Structure

PROJECT DEIMOS: BULK HEAD OPTIMISATION

ARES 2023: Project DEIMOS Internal Bulk Heads

COMING SOON

PROJECT DEIMOS: EXTERNAL ROCKET FINS