Amphenol PCD
Product Design
Engineering
Co-op
Beverly MA, July 2022 - January 2023
Torque Test Fixture
Designed a new fixture to test SJG connector's strength against an applied bending moment. Modeled in CAD using Creo PTC, and 3D printed early prototypes for test-fit with connector. Worked hands-on in machine shop to mill final fixture out of stock aluminum. Tapped screw holes to eliminate need for nut tightening/removal during quality testing. Added a counterbore for through-bolt that threads into a pre-existing testing rod.
SJG Connector
Juggernaut Case Modeling
Created a digital CAD model of a heavy-duty phone case from real physical version. Model was used by another company engineer to design a tight-fit mating connector. Used Keyence machine to photographically obtain high-accuracy measurements of case features to replicate in Creo.
Relay Socket Ultrasonic Welding Investigation
Investigated faulty ultrasonic welds between part components in response to part failures reported by Boeing. Conducted x-ray imaging and cut cross section into connector. Performed extensive pull-apart tests and analyzed stresses concentrations to recommend testing procedure updates. Along with process recommendations, modified existing fixture for stud-less connectors, and prototyped a new fixture for models with built-in studs. Worked with manufacturing engineering team to learn about ultrasonic weld design and optimization.
