PORTFOLIOPORTFOLIO

Ken Orr –Design Engineer/OwnerKen Orr –Design Engineer/Owner

ServicesServices 3D design engineering utilizing Pro/ENGINEER3D design engineering utilizing Pro/ENGINEER

• Complex Surfacing and AssembliesComplex Surfacing and Assemblies• SheetmetalSheetmetal• Mechanica, static only (structure & thermal)Mechanica, static only (structure & thermal)• Drawings (to ASME-Y14.5M standards)Drawings (to ASME-Y14.5M standards)• Packaging studiesPackaging studies• Simple fixture designSimple fixture design• Plastic part design (an Orrbit Design specialty)Plastic part design (an Orrbit Design specialty)• Project ManagementProject Management

PrototypingPrototyping• SLA or ObjetSLA or Objet• Urethane CastingsUrethane Castings• CNC machiningCNC machining• Finish Work (hand crafting, painting, etc.)Finish Work (hand crafting, painting, etc.)

Example – Patio UmbrellaExample – Patio Umbrella***Patent Pending******Patent Pending***

110V Powered Patio 110V Powered Patio UmbrellaUmbrella• Design included Design included

electrical housings, electrical housings, crank mechanism, and crank mechanism, and assembly.assembly.

• Prototypes supplied Prototypes supplied using SLA/Objet using SLA/Objet masters to generate masters to generate silicone molds for silicone molds for multiple cast parts.multiple cast parts.

Example – Cordless PhoneExample – Cordless Phone

Cordless Phone and Cordless Phone and charging basecharging base• Class-A complex surfacingClass-A complex surfacing• Generation of Front Cover, Generation of Front Cover,

Rear Cover, Battery Cover, Rear Cover, Battery Cover, Display Window, Keypad, Display Window, Keypad, Belt Clip for Injection Belt Clip for Injection moldingmolding

• Integration of electronics Integration of electronics with display lens, earpiece with display lens, earpiece connector, and battery connector, and battery charging contactscharging contacts

Example – Lawn EdgingExample – Lawn Edging

Wheat & Rock simulated Lawn EdgingWheat & Rock simulated Lawn Edging• Integrated intricate designs for injection molding Integrated intricate designs for injection molding

utilizing scan data with solid modelingutilizing scan data with solid modeling• SLA prototypes generated, and painted with SLA prototypes generated, and painted with

production intent colorsproduction intent colors

Example –RemoteExample –Remote Spa Remote ControlSpa Remote Control

• Class A surfaceClass A surface• Front Cover, Rear Cover, Front Cover, Rear Cover,

Battery Cover, Tactile Battery Cover, Tactile Keypad, Display Lens, Keypad, Display Lens, Rubber Key, Wall PlateRubber Key, Wall Plate

• Integrated Electronics Integrated Electronics includes display, thin tactile includes display, thin tactile keypad top keep water proofkeypad top keep water proof

• Prototypes supplied using Prototypes supplied using SLA/Objet masters to SLA/Objet masters to generate silicone molds for generate silicone molds for multiple cast parts in a multiple cast parts in a urethane material. Keypads urethane material. Keypads were prototyped by keypad were prototyped by keypad manutacturermanutacturer

Example – GatewayExample – Gateway Gateway for Schlage lock Gateway for Schlage lock

systemsystem• Class A surface for black Class A surface for black

injection molded partsinjection molded parts• Front Cover, Rear Cover, Front Cover, Rear Cover,

Battery Cover, Keypad Battery Cover, Keypad w/integrated light pipesw/integrated light pipes

• Integrated Electronics Integrated Electronics included PCB w/vertical included PCB w/vertical mount switches, RJ45 jack & mount switches, RJ45 jack & battery w/light pipe out frontbattery w/light pipe out front

• Prototypes supplied using Prototypes supplied using SLA/Objet masters to SLA/Objet masters to generate silicone molds for generate silicone molds for multiple cast parts in a multiple cast parts in a urethane material.urethane material.

Example – Caulk GunExample – Caulk Gun

Caulk Gun for 5.5oz tubesCaulk Gun for 5.5oz tubes• Class A surfaceClass A surface• Right & Left Covers, Tray with Right & Left Covers, Tray with

motorized screw feed motorized screw feed mechanism (Acme thd) with mechanism (Acme thd) with release trigger & gear system release trigger & gear system to drive feed mechanismto drive feed mechanism

• Integrated Electronics & battery Integrated Electronics & battery packpack

• Prototypes supplied using Prototypes supplied using SLA/Objet masters to generate SLA/Objet masters to generate silicone molds for multiple cast silicone molds for multiple cast parts in colored urethaneparts in colored urethane

Actual prototype

Example – TubsExample – Tubs

Bath & Spa tubs designed Bath & Spa tubs designed for Vac Forming from high for Vac Forming from high gloss sheet stockgloss sheet stock• Class A surfacingClass A surfacing• Continuity of rounds was Continuity of rounds was

crucial to this processcrucial to this process• Non skid on floor w/jet & Non skid on floor w/jet &

drain locationsdrain locations

Example – BenchExample – Bench

KLM Bench, commercial KLM Bench, commercial seating (8 person shown)seating (8 person shown)• Legs designed for Legs designed for

aluminum casting w/high aluminum casting w/high gloss polished finishgloss polished finish

• Designed to support up to Designed to support up to 450lbs per seat450lbs per seat

Example – Water CannonExample – Water Cannon

Toy Water GunToy Water Gun• Class A surfacingClass A surfacing• Hand run crank to pump Hand run crank to pump

waterwater• Base designed to adapt to Base designed to adapt to

a boat or docka boat or dock• Nearly 45 degrees of tilt Nearly 45 degrees of tilt

front/back and swivels full front/back and swivels full 360 degrees.360 degrees.

Example – Seat Back SailExample – Seat Back Sail

Sail for office furniture Sail for office furniture side chairside chair• Class A surfacingClass A surfacing• Each intersection had to Each intersection had to

be cut away and a surface be cut away and a surface blend created to meet blend created to meet designers requirementsdesigners requirements

Example – Swim DeviceExample – Swim Device

Wrist, Ankle & Head Wrist, Ankle & Head devices to monitor devices to monitor swimmersswimmers• Units are required to be Units are required to be

water proof to IP68 & air water proof to IP68 & air tight to 0atm in a cargo hold tight to 0atm in a cargo hold of a plane with no change in of a plane with no change in the unit when held in your the unit when held in your had at ground level.had at ground level.

• Top cover is an inset molded Top cover is an inset molded part with a 60 durometer part with a 60 durometer Santoprene material to allow Santoprene material to allow activation of 2 switches.activation of 2 switches.

Example – Medical DeviceExample – Medical Device

Medical deviceMedical device• Package electronics into Package electronics into

small enclosure with 3 small enclosure with 3 switchesswitches

• Top cover is an inset molded Top cover is an inset molded part with a 40 durometer part with a 40 durometer Santoprene material to allow Santoprene material to allow activation of switches.activation of switches.

• Back cover is formed metal Back cover is formed metal stampingstamping

Example – Mechanism CoverExample – Mechanism Cover

Mechanism CoversMechanism Covers• Develop new mechanism Develop new mechanism

covers for an office furniture covers for an office furniture chairchair

• Worked closely with Worked closely with Industrial Designers to Industrial Designers to capture design intentcapture design intent

• Created skeleton model to Created skeleton model to ensure proper form between ensure proper form between upper and lower coverupper and lower cover

Example – Chair Seat Example – Chair Seat DevelopmentDevelopment

Chair SeatChair Seat• Develop new seat for a new Develop new seat for a new

chairchair• Create structural plastic Create structural plastic

lower that mounts to cylinder lower that mounts to cylinder mounting plate. Worked with mounting plate. Worked with FEA to determine best rib FEA to determine best rib structure and wall thicknessstructure and wall thickness

• Create release lever for Create release lever for fore/aft adjustment and a fore/aft adjustment and a cover for the “no option” cover for the “no option” optionoption

Example – Chair Back FrameExample – Chair Back Frame

Chair Back FrameChair Back Frame• Develop new back frame for an Develop new back frame for an

office furniture chairoffice furniture chair

• Worked closely with Industrial Worked closely with Industrial Designers to develop best ProE Designers to develop best ProE class-a surfacingclass-a surfacing

• Parts had to have mating Parts had to have mating surfaces for a sonic weld surfaces for a sonic weld operation, this required the operation, this required the sharing of data between files sharing of data between files (publishing geometry)(publishing geometry)

• Because of the sharing of data Because of the sharing of data between file, the best method between file, the best method was use of a skeleton modelwas use of a skeleton model

Example – Cervical Spine Example – Cervical Spine DisplayDisplay

Cervical Spinal Display Cervical Spinal Display Model (C4-C6)Model (C4-C6)• Develop 2ft wide cervical Develop 2ft wide cervical

bone models for use in a bone models for use in a medical expomedical expo

• C4 and C5 to rock 10degrees C4 and C5 to rock 10degrees left/rightleft/right

• Design of motion mechanism Design of motion mechanism to fit within the main body of to fit within the main body of the bonethe bone

ContactContact

Orrbit Product Design LLCOrrbit Product Design LLC• Ken OrrKen Orr• 243 129243 129thth Ave. Ave.• Holland, MI 49424Holland, MI 49424• 616.240.7200616.240.7200• ken.orr@orrbitdesign.com• www.orrbitdesign.com