https://www.georgeroudebush.me/solar-town daily 0.75 2019-08-05 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564979371452-7UDO97H2JCI9C9E4FPLH/In_gallery.jpg Solar Neighborhood - Solar Neighborhood Configuration Project The goal of this project was to explore the possibility of making solar energy more usable and scaleable by creating arrays of panels which provide consistent power from sun-up to sun-down without an unwanted surge in the middle of the day. We where able to quickly test lots of configurations of solar panels with these scale models. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564979371452-7UDO97H2JCI9C9E4FPLH/In_gallery.jpg Solar Neighborhood - Solar Neighborhood Configuration Project The goal of this project was to explore the possibility of making solar energy more usable and scaleable by creating arrays of panels which provide consistent power from sun-up to sun-down without an unwanted surge in the middle of the day. We where able to quickly test lots of configurations of solar panels with these scale models. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564721799440-UJ0I8RC3YENQF6MRWA4L/IMG_2200.JPG Solar Neighborhood - The Experiment configuration I built this table and arm designed to swing across the table and shine light at different angles in order to simulate a day of sunlight. With this design, we where able to simulate a day of sunlight and collect data in fifteen minutes, which allowed us to design and test a number of configurations of the solar panels. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564979368988-ZS62M84EEHH2CX348CXG/With+Motor.jpg Solar Neighborhood - A cringe-worthy gearbox coupling... Duct tape can do everything right? Not pictured, me trying to determine if I was overloading my H-bridge by touching it… https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564721797994-DZAZ5GW9Y6XLE6SNNLOQ/IMG_2196.JPG Solar Neighborhood - Test configuration Using Some reflectors to try and direct some of the light towards the panels throughout more of the day. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564980951488-B4PDQAT03440B366DEER/IMG_2203.JPG Solar Neighborhood - Neighborhood Colaboration Wall solar panels are quite ineffective if they are near other houses, so we tried using reflectors on adjacent houses to shine light on traditionally hard-to-reach places. https://www.georgeroudebush.me/ski-building daily 0.75 2019-08-05 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564720088214-VLOVLEV4MVR1Z0XARHOT/IMG_2775.JPG Ski Building - "Research" There’s only one way to start designing skis…. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564720088214-VLOVLEV4MVR1Z0XARHOT/IMG_2775.JPG Ski Building - "Research" There’s only one way to start designing skis…. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564720449746-A8Q1ALCWY0PRC2RXWAET/Screen+Shot+2017-11-16+at+2.46.26+PM.png Ski Building - Some Reading and some math until finally... https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564719471603-KE94O0G4PMVNADNG52QB/IMG_2955.JPG Ski Building - I decided on a shape I played around with the length, thickness profile, side-curve, material, width until I had what I thought would be a good ski for me. Then, I laser cut the profile to transfer onto the various materials I’d put in the ski https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564719556463-FIGGPYDRK2NNLERV8OQY/IMG_3018.JPG Ski Building - Now on to building them! The core is the most interesting part of the ski. It gives it it’s characteristic springiness and particular stiffness, and naturally it’s also the hardest part to make. I made mine out of solid pieces of poplar — Most ski manufactures glue together a set of stringers and profile it from there. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564719338301-JPVJG0Z4ZA3J55G74C6K/IMG_3043.JPG Ski Building - Core Ready for profiling My Home-made profiling jig. The rails on the side are cut to the shape of the ski. As I slide my router across the top, the profile appears! https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564719608166-EUSL83O8RAXZKDLAZDD6/IMG_3022.JPG Ski Building - Next step....Layup! Bottom mold for shaping the finished ski. You can see the top mold in the background. Once everything was laid out and lathered with epoxy, I pressed the two sides of the mold together with some ratchet straps and… https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564722532628-5M2222O0ZI2KEA4TV66Q/ezgif.com-gif-maker.gif Ski Building https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564719630379-44H49R39P15HT6554WST/IMG_9122.JPG Ski Building - Blank ski! Ready for finishing https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564719904949-64RCR6ADAZMRWF45YUE7/IMG_3062.JPG Ski Building - First ski, complete with my janky paint job https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564720976108-BJLRQVM9BJYC5TYCGBX2/IMG_3184.JPG Ski Building - After making my first ski, I figured I'd go and look into how the pro's do it Just my luck! Parlor ski’s in East Boston has a ski building class. I got to make a (now actually functional) set of skis which I ride to this day. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564719893957-6OE1Y1YL5FKATHA9ZGFI/IMG_3163.JPG Ski Building - Gluing down the edges https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564719901788-WCRZOG1OA5IT8COQ73JQ/IMG_3166.JPG Ski Building - Gluing the core from maple stringers https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564719898458-E325JRVAHG09W5GQGBH2/IMG_3162.JPG Ski Building - Topsheet Design https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564722514271-ZJFDX82VO4UNTM8157DA/ezgif.com-gif-maker.gif Ski Building https://www.georgeroudebush.me/2007-robot daily 0.75 2019-09-20 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1566503646287-R896ZCMJSP9R5LXY9FGH/IMG_1046.JPG 2.007 Robot! - Design and Manufacturing (2.007) 2.007 revolves around a robot competition. Given a kit of materials, including various stock aluminum, electronics, plastics, ect. Each student individually designs and builds their very own robot, which takes on a set of competition tasks laid out at the beginning of the semester. This was a picture of me right after getting knocked out of final competition bracket. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1566503646287-R896ZCMJSP9R5LXY9FGH/IMG_1046.JPG 2.007 Robot! - Design and Manufacturing (2.007) 2.007 revolves around a robot competition. Given a kit of materials, including various stock aluminum, electronics, plastics, ect. Each student individually designs and builds their very own robot, which takes on a set of competition tasks laid out at the beginning of the semester. This was a picture of me right after getting knocked out of final competition bracket. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1566503246637-EGCDRGCRIM81IHR1TO7Q/IMG_1029.JPG 2.007 Robot! - The Competition Board The robots started on the first level of the lunar lander, drove down two ramps to the floor of the gameboard. Along the way robots had the chance to plant a flag. Once it got down to the floor you could pick up rocks and put them in a number of places. You could also spin the “APS charger” for some number of points, or remove “excess fuel cells” from the outside of the lander. My robot focused primarily of picking up rocks and driving them back to the lunar module. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1566503048817-ZF8NHIR3BWGZZZ2T8T7Q/IMG_5609+%281%29.JPG 2.007 Robot! - The drivetrain I spent most of the semester focusing on the design and construction of the drive train of my robot. It wasn’t always suppose to be this way, but proved to be way harder than I initially anticipated, so I sunk most of my time into it. This was iteration one. It worked great, so long as the timing belts didn’t ride themselves off the edges of the wheels. Oh, and it was really tough to assemble… https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1568983709186-QX42CF7M4CJCY2E3QKY0/IMG_5615+%281%29.JPG 2.007 Robot! - Iteration 2 So I figured that the reason my treads where slipping off was misalignment. In order to get the alignment right, I made each half of the wheelbase for the robot out of a single square bar. I hoped that this would guarantee alignment, and also make the robot easier to assemble and test. The alignment was fantastic, the assembly was straightforward, but the wheels still slipped off… Back to the drawing board. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1566504145057-KDA0OYPVNU0VHMR51JMU/IMG_5709+%281%29.JPG 2.007 Robot! - Final iteration As it turned out, misalignment was not the trouble. Instead, the problem was with my timing pulleys: I had laser cut each one out of a single piece of 3/4 inch plywood, which meant that the whole toothed surface was tapered. As the timing belt spun, it rode up the very slight slope of the plywood and eventually off the wheel. For this iteration, instead of using a single piece of plywood, I cut each pulley out of two pieces of acrylic, and oriented the taper outward, in order to center the timing belt. I also laser cut my own wheels, which now raised the timing belt off the ground in order to keep it from sliding off as the robot turned. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1566502651287-VBYTEF2I20AWP5G8I2RX/Final%2BCAD.jpg 2.007 Robot! - Final CAD model But alas, the tread design suffered from a great deal of unmodeled friction. After tensioning the belt, it was impossible to make it up the hill. So after 2 months of painstaking work on the tread concept I ditched it, it was time for a re-design. In this version, instead of connecting the wheels with a timing belt, I wired both motors on one of the sides in parallel to the motor driver. This robot was slower than my initial design intent, but I decided that predictability was very important, and the high torque motors kept the robot’s speed extremely consistent. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1566501965881-35MEALJPJKZRTISJ2BUT/IMG_5730.JPG 2.007 Robot! - The final robot... After finishing the CAD model, I got around to building and testing the robot. I had about a week, so I added the block on the left, which housed an arduino controller, the PS2 controller receiver, and a little wedge to carry a flag. I also added those two aluminum wings on the side to stop rocks from falling off the sides as the scooper tossed them in. https://www.georgeroudebush.me/pogobot daily 0.75 2023-02-05 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1567613260916-S94JG6UQM2RADPQVUAX7/IMG_5626.JPG Pogo-Bot - We designed and built a robot to test a planner and controller which directly minimizes the theoretical risk of failure for each step. For some more detailed information about things that have come out of this project, I’ve attached some of the finished content that has come out of this project. You can download my undergraduate thesis, which goes into painfully explicit detail on the mathematics behind the risk-gradient planner and controller. An overview of the project with some more detail Documentation of Robot’s Mechanical Design Choices A poster on some experiments that I ran on one of our initial prototypes And a poster about part of the work I did on the controller development. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1567613260916-S94JG6UQM2RADPQVUAX7/IMG_5626.JPG Pogo-Bot - We designed and built a robot to test a planner and controller which directly minimizes the theoretical risk of failure for each step. For some more detailed information about things that have come out of this project, I’ve attached some of the finished content that has come out of this project. You can download my undergraduate thesis, which goes into painfully explicit detail on the mathematics behind the risk-gradient planner and controller. An overview of the project with some more detail Documentation of Robot’s Mechanical Design Choices A poster on some experiments that I ran on one of our initial prototypes And a poster about part of the work I did on the controller development. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1603677640593-GQMQLDMCDULTJXA24NGJ/IMG_5627.JPG Pogo-Bot - Revision 2 of the pogobot The clear acrylic plates would not be nearly strong enough for our intended use for it, but gave us a clear window into the internals for debugging. This model was used to test the fidelity of the leg’s force controller, essential for the proper performance of the robot under the risk controller. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1603677663349-LKSLKY0TE0BHB4JM8W4K/Full+CAD.PNG Pogo-Bot - CAD for Revision 3 of the Pogo-bot The round-body allows for the internal space to add a second stage to the reaction wheel. The 1:3 gear ratio from the reaction wheel motor to the reaction wheel gave us the runtime we need to perform our most aggressive planned actions. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1603677673564-5QPFHXFOGTHY8ODWVP9R/Reaction+Wheel+CAD+side+view.PNG Pogo-Bot - Side view of the reaction wheel drivetrain https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1603677697978-LLNV9SV2D61J8U8FG9AA/Reaction+Wheel+CAD.PNG Pogo-Bot - Reaction wheel mechanism Belt drove with a ratio of 1:3 from the motor to the Reaction wheel, this was the most complex mechanism on the robot. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1603677863366-P4PPDHHL49ZBEMJWOTB8/PogoBotBody.PNG Pogo-Bot - The Assembled Revision 3 body This time outfitted with steel plates for added rigidity, this version of the pogobot has all of the features internally which we would need for our testing. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1603677867024-SOSS9ONAD3GDLOH276UM/FullyAssembled.PNG Pogo-Bot - Balance Testing Unfortunately, the end of my time at MIT came before the robot was ready to be fully tested. We did manage to get the robot to maintain an upright position for 10 seconds or so before the reaction wheel saturated. An offset in the orientation estimate would need to be included to account for the CG not being directly above the leg. https://www.georgeroudebush.me/toy-product-design daily 0.75 2019-08-06 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564985046154-O41XL0ARQ5JH6NJ7QKJ8/ScetchModels1.jpg Toy Product Design - Toy Product Design Toys. Who knew that you could do real hard work dedicated to making toys. Toys! This toy product design class took my team and I through the full design and build process around making toys, any toy. As may be evident, I really enjoyed this class… https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564985046154-O41XL0ARQ5JH6NJ7QKJ8/ScetchModels1.jpg Toy Product Design - Toy Product Design Toys. Who knew that you could do real hard work dedicated to making toys. Toys! This toy product design class took my team and I through the full design and build process around making toys, any toy. As may be evident, I really enjoyed this class… https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564985036531-I4JW5BX7Y1HTBL31D878/hedgehog-3.jpg Toy Product Design - The Magic Blocks V1 Growing up, building blocks where my favorite toy. Your creations are only limited by your imagination and the physically possible. With the magic blocks, we wanted to give the impression that those pesky rules like gravity don’t apply, creativity would know no bounds! The blocks are laser-cut out of plywood, and in each of the four corners a small - powerful magnet is inlaid to allow the blocks to stick to each other at odd angles, in awesome ways! https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564985043219-LWNPUD11MVRF2RS7IHDJ/hedgehog-4.jpg Toy Product Design - Magic Blocks V2 Velcro is awesome. With these foam blocks we where able to build high and wide, sideways and upside-down. Incredible feats of engineering at your fingertips! https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564985044784-XA8X0TTT5E6A3HES3ZZD/hedgehog-5.jpg Toy Product Design - Play testing at the children's museum Who else but young children to enlist as an expert on toy development! https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564985046303-CRRVQMC9WO79EOWQ7WTP/teams-m-8.jpg Toy Product Design - Team Hedgehog and the infection game By the end of the semester we’d pivoted from a building toy to a competitive game! Infection, inspired by the velcro-based mechanic of our previous ideas, was lighthearted, stylish, and a whole lot of fun to play! https://www.georgeroudebush.me/rise daily 0.75 2022-12-06 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342687127-X8CQVCVC7LBNBQETA57F/Rise+Portfolio+Banner.png Rise https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580340226054-DZKI30BF3D53TR1ZVWVZ/Slide3.PNG Rise https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342420159-UT9FVM66BPAITYU1X73D/Portfolio+Title+slide.png Rise - rise After a half-semester of researching and developing a product concept which we could take to the alpha-prototype stage, we settled on rise, the easy access oven rack. Final Presentation Video https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342712263-9JLFEKZ5TDR7ERKPYJ34/Slide1.PNG Rise - Sketching and concept development Each person on our team was tasked with creating a variety of sketched design concepts to stimulate discussion for how we should move forward on the project. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1670335418358-BIDNM7NXAV92AZ5DYP0S/image.jpg Rise - Sketch Model Early in our development, we created this sketch model out of plywood and foamcore. This model was extreemly successful in presenting our product concept to reviewers and potential customers. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342712557-SLCDTTNQ63UDKLUN7OT8/Slide3.PNG Rise - Initial prototype CAD model A simple CAD model to demonstrate the physical architecture and integrated design for our first prototype. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342713274-V3XSKPNMDHE1F3W4LBMK/Slide4.PNG Rise - Critical Paths As part of my role on the team, I was tasked with ensuring that we had a solid schedule for the development of the prototype. I used a CPM to work out for myself and demonstrate to my teammates where we were in the project and delegate effectively. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342720687-UXEBPMYQCDGVKVZELHWL/Slide5.PNG Rise - First Prototype We built our first prototype by retrofitting off the shelf oven sliders with a swinging platform. The mechanism was actuated by two windshield wiper motors. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342720566-XCS0WT39PQL18Z6U4S57/Slide6.PNG Rise - Details of first prototype How to create effective rotating connections was a critical aspect of our initial prototype. In this iteration we used PTFE bushings, which we eventually found where too low friction and lead to swinging. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342722405-5RIDRYYPFUDIAFMIRGTN/Slide7.PNG Rise - CAD model for alpha prototype After conducting more user testing with our first full prototype, we refined our design to address some of the critical issues our users had identified. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342722264-9MBEAKFR91SZ4DKS0ZS9/Slide8.PNG Rise - Behind The Scenes One major advantage of the driving mechanism we chose was that it could be completely concealed in the oven cavity and took up no more space in the oven than the sliders themselves. The gearbox drives the motion of the rack in two degrees of freedom, which creates the desired “up and out” motion that our users liked. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342723726-3PEJZYELX4HXDMHCYY81/Slide9.PNG Rise - Slider Design As part of the development of our alpha prototype, we decided to design our own sliders which took up less space inside the oven and allow us to optimize the trajectory of the oven rack according to our useability goals. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342725713-HD41FRM6E1YH7BBN7EV4/Slide10.PNG Rise - Gearbox Driving the four-bar rack mechanism is a worm-gearbox. It provides a 100:1 reduction and prevents the rack from being back-driven. The output shaft is well supported by two large bearings, and the output forces on the shaft are configured such that very little net bending force is applied to it. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342728629-88G87NNWUECNA6DPOEH3/Slide11.PNG Rise - Gearbox Installation Once we fabricated the gearbox, we mounted it behind the oven and routed the cables from inside the oven to the back of the oven. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342734211-NWI9DO07TMXA5VGV6ZFP/Slide13.PNG Rise - Alpha Prototype After a couple of sleepless nights, we had a completed alpha prototype for rise. As with any prototype, we had some issues with lifting the full load, but functional enough to demonstrate the desired features for the final presentation. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342732270-LCOYQDHVF8OJGMVQGNCV/Slide12.PNG Rise - 2.009 Gallery and other links 2.009 Final Presentation Rise Brochure https://www.georgeroudebush.me/remote-control-car daily 0.75 2020-11-02 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1592173911926-PCH79QD9Y7B69NB5V667/Slide2.PNG Remote Control Car - Covid-19 Lockdown Project Partially to maintain sanity, partially to hone in my 3D printing and Mechanical design skills, mostly because cars are cool and this was fun, I am excited to share my (mostly) 3D printed remote control car. This is still a work in progress, slowly building up complexity through a number of design iterations. The goal is to design a remote control car from the ground up with AWD, full suspension, and enough power to make it wicked fun to drive around. I’ll probably share my design on Thingiverse when all is said and done, but for now the development continues! https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1592173911926-PCH79QD9Y7B69NB5V667/Slide2.PNG Remote Control Car - Covid-19 Lockdown Project Partially to maintain sanity, partially to hone in my 3D printing and Mechanical design skills, mostly because cars are cool and this was fun, I am excited to share my (mostly) 3D printed remote control car. This is still a work in progress, slowly building up complexity through a number of design iterations. The goal is to design a remote control car from the ground up with AWD, full suspension, and enough power to make it wicked fun to drive around. I’ll probably share my design on Thingiverse when all is said and done, but for now the development continues! https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1592173909349-RV8XQ9CXB3O0ZV0IIWO6/Slide3.PNG Remote Control Car - Planning the prototypes: Step 1: Prototype Ackerman Steering Geometry. Step 2: Prototype remote control, electronics and BLE connection between remote and the car. Step 3: Add suspension to front wheels, while maintaining Ackerman Geometry Step 4: Prototype Differential gearbox as the first step towards AWD Step 5: Add a motor to the front wheel assembly, while maintaining the steering and suspension. Step 6: Add suspension to back wheels, integrate back and front wheels into a single design. Step 7: Optmize, make the car better faster stronger! https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1592173915624-1WEOKLN216VZU7SRDOZ8/Slide4.PNG Remote Control Car - Rev 1 My first prototype as a very simple car with no suspension and only rear-wheel drive. Used this prototype to develop the controls and electronics for the car, as well as understand the limitations of the PLA I’m using to make these quick prototypes. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1592174774807-8K7RGL81ODXP1J6YF9GB/Slide5.jpg Remote Control Car - Rev 2 Large design overhaul in a lot of aspects. I spent some time working on understanding the capabilities of the car given the motors I’m using and found that it would be beneficial to the stability and acceleration of the car if I increased the overall footprint. This also allowed me to take some very small plastic parts and make them more rigid and durable, as I tested the limits of what the PLA could handle. I also experimented with a sort of clam-shell design to improve assembly time and the overall rigidity of the car. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1592173917825-M2MPDLIIVE8UW14HDK5Z/Slide6.PNG Remote Control Car - Differential Two revs of differential gearbox prototypes. Added the Miter gear to the outside to keep the motor from shifting the CG and moments of inertia of the car too far from the centerline. The miter gear also helped add the flexibility I needed to fit the steering, powertrain, and suspension components into the front wheel assembly. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604276586385-2X61PYBAJTRBNDPUPKTV/IMG-0335.jpg Remote Control Car - Rev 2 for differential gearbox. The size of the gearbox is driven by the resolution of the 3D printer. A modulus of 1 (metric) is the smallest pitch I managed to print. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604276110662-FDKON0WJQQ81QJ4IPEHL/IMG-0337.jpg Remote Control Car - Four Wheel Drive front-end The biggest challenge with making a four-wheel-drive car is to fit a differential, motor, and steering linkage into the front end. The next biggest challenge is fighting that space constraint while maintaining the strength and stiffness of the transmission. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604276824083-E5545GFRS35B0TD94BVW/IMG-0370.jpg Remote Control Car - Back end of the fully-suspended car I tried to reuse as many components for the back end as the front end, as these wheels don’t need to rotate like the front wheels do to steer, so it’s a much simpler overall mechanism. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604276608399-O1GHE2YIEFPH9H0GOXF8/IMG-0366.jpg Remote Control Car https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604276613172-0FO1TIUAU2ZKY297TT0G/IMG-0368.jpg Remote Control Car - Rear end universal joint and suspension linkage The PLA universal joint has given me lots of trouble, still evaluating whether or not it’s a feasible challenge. https://www.georgeroudebush.me/goofy-pumpkin daily 0.75 2020-11-04 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604256771806-KTDXKU4BH17OVCYOEB83/62526076786__95927FC9-99A4-480F-9E00-5D04FB766E04.JPG Goofy Pumpkin - Jack-o-lanterns are cool, but with extra time on my hands, why not go the extra mile... https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604256771806-KTDXKU4BH17OVCYOEB83/62526076786__95927FC9-99A4-480F-9E00-5D04FB766E04.JPG Goofy Pumpkin - Jack-o-lanterns are cool, but with extra time on my hands, why not go the extra mile... https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604256824281-AGO4ABYE75BTB6VJBYO5/IMG_0503.jpg Goofy Pumpkin - LEDs are better than candles, but I think I can do better. Yup, that’s an ultrasonic sensor on his chin. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604256669955-O64W43T4QXQGL03B2ZVB/image-asset.jpeg Goofy Pumpkin - The Sloppy electronics to make my pumpkin the best one ever. A 2S2C LiPo battery to drive the vibration motor, a Red Lithium USB battery to power the MCU, LEDs, ultrasonic sensor and control the motor driver https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604256863854-FESJPW1TXURA3LPD283P/ezgif.com-gif-maker+%281%29.gif Goofy Pumpkin - With sound, you could hear the pumpkin hopping across the table when someone gets close Scary enough to surprise my roommate? indeed :) https://www.georgeroudebush.me/multicolored-lamp daily 0.75 2020-12-27 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609083073334-XH8NVPX3SD325O4L2K7C/image.jpg Multi-colored lamp - My multi-colored oak lamp With some scrap wood, a few extra electronics and a little bit of fabric, I put together this lamp as a Christmas present. The controls are embedded directly into the wood and sensed via a capacitive touch chip. The LEDs are individually programable, leaving the opportunity for more complex color pallets in the future. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609083073334-XH8NVPX3SD325O4L2K7C/image.jpg Multi-colored lamp - My multi-colored oak lamp With some scrap wood, a few extra electronics and a little bit of fabric, I put together this lamp as a Christmas present. The controls are embedded directly into the wood and sensed via a capacitive touch chip. The LEDs are individually programable, leaving the opportunity for more complex color pallets in the future. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609020522871-LJDDYKV3RYZCX9DNNBG4/IMG_0656.jpg Multi-colored lamp - The electronics A simple MCU and a capacitive touch chip allowed me to embed the controls directly into the wood. I think it improved the simplicity of my design and the seemless integration of electronics into the woodwork is unmatched as compared to other button types. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609020528459-C9ZJIDC631DBYPHMWBPU/IMG_0659.jpg Multi-colored lamp - LED strip to drive the light https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609020527605-KXOS89IMWQH23J7H6HJP/IMG_0660.jpg Multi-colored lamp - Wood burned button panel The wood-burned buttons keep the raw wood feel to the buttons and complemented the stain nicely. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609020516540-I0PQ4M7MHS1J6PZBNP5F/IMG_0661.jpg Multi-colored lamp - Wood frame for the fabric First step in completing the shade for the lamp https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609021809601-Z9Y9F4PNB541BA1X2EDN/ezgif.com-gif-maker+%281%29.gif Multi-colored lamp - The electronics interface You can power on, change the brightness and color of the LEDs with the buttons on the front https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609020516397-KRI1KPT8N91FI9ITHG32/IMG_0672.jpg Multi-colored lamp - Final product, ready for giving! https://www.georgeroudebush.me/home-sofia daily 1.0 2025-05-09 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564460773645-8RI6C9A5E9N15E8F2D2G/ScetchModels1.jpg Welcome https://images.squarespace-cdn.com/content/v1/58d00f106b8f5b01c8e73f52/1491858427382-L46N6OML0EQRY4L20YNX/color-3.png Welcome https://www.georgeroudebush.me/mechatronics-at-natel daily 0.75 2023-02-05 https://www.georgeroudebush.me/explore-projects daily 0.75 2023-01-17 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604257088333-EYTBW2DNRDP8B85XHV2Q/ezgif.com-gif-maker+%281%29.gif Explore Projects https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/f8716848-1e62-48da-856d-6f919ca7732e/Self-leveling+stage.PNG Explore Projects - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564719338301-JPVJG0Z4ZA3J55G74C6K/IMG_3043.JPG Explore Projects https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580100546673-DNLT5I5V03XBY459MBBS/DSC_3662.jpg Explore Projects https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1566501965881-35MEALJPJKZRTISJ2BUT/IMG_5730.JPG Explore Projects https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580100942734-S2RY0TL4MZBGKP7FH2Z4/RHT.PNG Explore Projects https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580101465873-G83M2P02QC3ODY02C9F6/IMG_5626.jpg Explore Projects https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609022026520-NNK7XU7JY6X6G7O1TVKZ/image.jpg Explore Projects https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1592173911926-PCH79QD9Y7B69NB5V667/Slide2.PNG Explore Projects https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564979371452-7UDO97H2JCI9C9E4FPLH/In_gallery.jpg Explore Projects https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1564985046303-CRRVQMC9WO79EOWQ7WTP/teams-m-8.jpg Explore Projects https://www.georgeroudebush.me/about-me daily 0.75 2020-11-04 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604277561085-FD8QGI3ZM30MHJZYHMOT/Headshot.jpg About Me https://www.georgeroudebush.me/bedside-lamp daily 0.75 2023-11-09 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609022026520-NNK7XU7JY6X6G7O1TVKZ/image.jpg Bedside Lamp This Christmas present for my fiancé quickly spiraled out of control — One minute I was making a simple little square lamp from some wood cutoffs and spare electronics — then I scope-creeped my way into adding capacitive touch buttons, colors and dimming capability. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609020516540-I0PQ4M7MHS1J6PZBNP5F/IMG_0661.jpg Bedside Lamp Putting my mini-clamps to work. Also love the look of the endgrain :) https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/b6e19bdc-2b1b-464d-8058-4ed56b4201dd/IMG_0659.jpg Bedside Lamp One added bonus of arranging the LEDs like this is that they project a very cool grid pattern on the ceiling above the lamp! We love unintended features. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1609021809601-Z9Y9F4PNB541BA1X2EDN/ezgif.com-gif-maker+%281%29.gif Bedside Lamp The scope creep payed off, isn’t this fun! https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/e6319861-f18a-4d65-a2a5-b2f236fe36d6/IMG_0656.jpg Bedside Lamp Did this project require an ARM cortex M0 processor and an RFM69HCW RF Transmitter-receiver? No. No it did not. https://www.georgeroudebush.me/the-mechatronic-pumpkin daily 0.75 2022-12-23 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604256824281-AGO4ABYE75BTB6VJBYO5/IMG_0503.jpg The Mechatronic Pumpkin Can your jack-o-lantern shake violently upon the approach of an unassuming trick-or-treater? Spew mist out of it’s creepy face? Does your jack-o-lantern rot in hours instead of days because turns out that adding moisture to the inside of a pumpkin supercharge it’s bacteria growing capability? https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604256771806-KTDXKU4BH17OVCYOEB83/62526076786__95927FC9-99A4-480F-9E00-5D04FB766E04.JPG The Mechatronic Pumpkin This might be the dumbest thing I’ve ever made. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604256669955-O64W43T4QXQGL03B2ZVB/62545549056__E290FCD0-3B30-4611-AF8C-FD40A221A61F.JPG The Mechatronic Pumpkin For the record, my electronics prototyping looks a lot better now than it did then. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604257088333-EYTBW2DNRDP8B85XHV2Q/ezgif.com-gif-maker+%281%29.gif The Mechatronic Pumpkin Introducing the Jack-O-Lantern of the 21st Century! It’s got it all folks, multicolored LEDs, an Ultrasonic mister, and a motion sensor! https://www.georgeroudebush.me/rc-car daily 0.75 2023-11-09 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1592173911926-PCH79QD9Y7B69NB5V667/Slide2.PNG RC Car Mistakes where made on this prototype — It’s not nearly as polished or as robust as I’d hoped. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604276613172-0FO1TIUAU2ZKY297TT0G/IMG-0368.jpg RC Car Because of the size of the differential, the parallelogram linkage for the suspension couldn’t be centered on the differential output, so the middle of the U-joint has a telescoping shaft. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/e49bb8c5-3af4-492c-bc15-35b2b135b3b9/IMG-1282-Original.jpg RC Car The most recent iteration of this design hasn’t gone anywhere for the last two years, so it’s currently sitting in CAD purgatory until I’m bored again at work and decide to pick it up again. To introduce a bit more challenge to the design and more efficiency and reliability to the printing process, all the parts are printed without support. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604276110662-FDKON0WJQQ81QJ4IPEHL/IMG-0337.jpg RC Car Partially assembled front steering and drivetrain https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604276586385-2X61PYBAJTRBNDPUPKTV/IMG-0335.jpg RC Car A view of the differential pre-assembly https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1604276824083-E5545GFRS35B0TD94BVW/IMG-0370.jpg RC Car Probably the most interesting thing about this here car is the drivetrain. It incorporates some cool mechanisms to transfer power to the wheels via a differential, but this is really only a “test fit” version, a useable drive mechanism will need to be much more robust than these tiny PLA parts. https://www.georgeroudebush.me/2009-rise daily 0.75 2023-11-09 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342734211-NWI9DO07TMXA5VGV6ZFP/Slide13.PNG 2009 Rise - By designing for our lowest mobility customer, we created a product that everyone is excited about Rise is for passionate home chefs with varying degrees of mobility to get the most out of their ovens! The set of 3 racks swings out of the oven to give people easy access to their food, and streamline the cooking experience! https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342722264-9MBEAKFR91SZ4DKS0ZS9/Slide8.PNG 2009 Rise And design a mechanism to lift the rack out of the oven https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342720566-XCS0WT39PQL18Z6U4S57/Slide6.PNG 2009 Rise - Make it stand out This prototype didn’t look great but that wasn’t the point, we learned a whole lot about the machine at this step! https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342712263-9JLFEKZ5TDR7ERKPYJ34/Slide1.PNG 2009 Rise It all started with concept sketches and brainstorming https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/c375be1f-ccf3-4980-a420-2810b7c189f0/_TNQ3302.jpg 2009 Rise - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/755e0cd3-a3eb-4d91-9c5b-25c91269beb7/_TNQ3299.jpg 2009 Rise - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342728629-88G87NNWUECNA6DPOEH3/Slide11.PNG 2009 Rise - Make it stand out Then it was time to get busy in the shop https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342723726-3PEJZYELX4HXDMHCYY81/Slide9.PNG 2009 Rise Because we wanted to be able to use the inside of the slider to mount additional oven racks, we designed and built our own custom sliders. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/6d3783a5-627c-47cc-918c-0b3c540a3f34/Vianna-using-rise.jpg 2009 Rise - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/e97cdac8-de9b-412d-8c97-745d580d055f/risen.png 2009 Rise - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/5b089e5d-e89c-4c5d-8455-52705129e541/DSC_3713.jpg 2009 Rise - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/dc33fc57-d35d-48c6-b9de-ee6c61d478ab/IMG_9040.jpg 2009 Rise - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/aa5aea9d-1102-4f4d-b090-ce7ced64aa9e/slidingoutstraight.png 2009 Rise - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/434984c5-bddc-472e-b0a7-3a29e0925ffe/IMG_9034.jpg 2009 Rise - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580100546673-DNLT5I5V03XBY459MBBS/DSC_3662.jpg 2009 Rise - Make it stand out The final test for this mechanism was to lift a turkey in and out of the oven! https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/a8197d0d-162a-4013-a9a5-f31279b94851/risingout.png 2009 Rise - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/cdac5d2f-e885-4d30-8116-5ae3884cc236/IMG_9020.jpg 2009 Rise - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342712557-SLCDTTNQ63UDKLUN7OT8/Slide3.PNG 2009 Rise Then to some conceptual CAD https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/1580342722405-5RIDRYYPFUDIAFMIRGTN/Slide7.PNG 2009 Rise - Make it stand out A more complete CAD model and a refined design followed https://www.georgeroudebush.me/milwaukee-tool daily 0.75 2023-11-09 https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/31c743c6-5a25-4ae1-b868-201c05883ddd/Screenshot+2023-11-02+085840.png Milwaukee Tool - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/c081ec45-6724-443d-be2d-c6b1b3139c61/Screenshot+2023-11-02+085808.png Milwaukee Tool https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/c8c29bf4-9395-49cf-aac4-d9ef29c50cfd/Screenshot+2023-11-02+085726.png Milwaukee Tool https://images.squarespace-cdn.com/content/v1/5d3fc1101d85ce00019852b8/21aa0f5d-b61c-47f5-b325-11940cefc9b2/Robo-spot.PNG Milwaukee Tool - 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