MORGAN FLETCHER
Mechanical Engineering Portfolio
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PROJECT 1
IPhone case
The goal of this project was to design a high impact resistant phone case for the IPhone 10 and IPhone 13 following the Apple accessory design guidlines. This case was originally 3D printed using thermoplastic polyurethane (TPU) but was later changed to ePLA ST as it reduced production times by 60% and is a biodegradable filament that still offers high impact resistance.
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PROJECT 3
3D Printer Hotend Cover
This project involved designing an aluminium 3D printer hotend cover that was lighter and more aesthetically pleasing. This reduced weight improved the print quality by minimizing vibrations at high speeds.
PROJECT 5
Injectionmoulded Buckle
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This project involved designing a plastic buckle that could be injection moulded. The design is based on the YKK LB-LVS buckle and was modeled in Solidworks using photos as a reference. After the buckle had been designed in Solidworks, a feasibility test was done using FEA to validate the design. A prototype was then made using 3D printing.
A second feasibility study was conducted to check the draft angles on the part to ensure the buckle could be manufacture with injection moulding. Once this test was completed the final mould could be designed.
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PROJECT 6
WAVe LAMP
This was a personal project in which I designed a modern lamp that used a strip of LED lights. The lamp was designed in SolidWorks and optimised for 3D printing to improve print times by reducing print head travel. The first iteration was printed using PLA but due to the low melting temperature this was changed to PETG.
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PROJECT 8
Rocket Stabilization System
The goal of this project was to create a stabilization system that used an Arduino and a 3 axis accelerometer and gyroscope. The active stabilization allows the rocket to constantly monitor its position relative to its starting point and correct back to a vertical position.
Professional Work Projects
I have previously worked on a number of professional projects within the automotive and aerospace industries. However, due to non-disclosure agreements I am unable to showcase the exact projects I was working on. Therefore, I have recreated similar projects to show my work.
This is me
The Design Process
PROBLEM
At the core of every project is a problem. I first define the problem and identify what the project needs to achieve.
RESEARCH
I explore every facet of the problem. I analyse the projects cause and effect, its priorities, competitors and their approach, possible materials, etc.
DESIGN
I generate and refine tangible solutions until one emerges that meets the design criteria. I will then prototype this idea to test it.
PRODUCTION
I will create the final model that solves the problem