B Y U C A P S T O N E

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Scott Stubbs

Product Development Portfolio

9 Design Skills Represented by Several Projects

Discovering – Find existing knowledge and skills, find out customer needs.

Creating – Knowledge generation and restructuring

Representing - Graphical representation of data

Modeling – Calculations to justify ideas

Prototyping – Physical approximations of ideas for further justification

Experimenting – Measuring the performance of the product

Evaluating – Interpretation of the quality of the design

Deciding – Using information to decide a course of action

Conveying – Sharing design information with necessary individuals

BYU Capstone Project 2015-16Discovering

• Invasive examination of existing products• Internet search of existing products• Patent Search for pitch training devices

Sunstone Engineering – Design Engineer 2011 - Present

Exploring the design space for an

adjustable laser holder.

Creating

Creating Sunstone Engineering – Design Engineer 2011 - Present

We needed a high wattage, low resistance (33 ohm) resistor to

discharge ultra capacitors. Existing resistors were either very

expensive or didn’t have the required electrical properties.

Existing Resistor

Initial Sketch

Final Product - Nichrome ribbons with aluminum heat sink

Creating Sunstone Engineering – Design Engineer 2011 - Present

Existing linear actuators of the correct size are too

slow for the intended application, so I

developed an actuator with a motor and Acme

thread that can reach the intended speeds.

Existing Actuator 3D CAD Rendering

Prototype I Machined for Testing

Creating Sunstone Engineering – Design Engineer 2011 - Present

This rotary tool is designed with the Dremel in mind, but is specifically made to sharpen

TIG welding electrodes at the correct angle and

position.

Prototype

Existing Product

The electrode approaches the

diamond wheel at the ideal angle and

position.

Initial Designs

Representing Sunstone Engineering – Design Engineer 2011 - Present

Weld Heads designed to perform spot welds (using micro TIG technology) on conductive material such as copper battery tabs and

aluminum sheeting.

Representing Sunstone Engineering – Design Engineer 2011 - Present

Opposed Spot Weld Head designed to replace a wider profile version that had issues with electrode deflection

and a high cost of goods.

Representing Sunstone Engineering – Design Engineer 2011 - Present

“Micro” weld head designed to deliver continuous forces up to 3000gF. Replaces a version that has arced electrode motion (instead of linear up and

down) and that takes 10 times longer to assemble.

Representing Sunstone Engineering – Design Engineer 2011 - Present

Impact Stud Welder designed to weld the studs onto earrings. Improves upon existing units by delivering closed loop feedback, laser location, and motor driven retract/impact (older models use springs).

Representing TES Equipment Supplier – Technician 2006 - 2011

These assemblies were created by measuring each

individual part of an encapsulation machine and

making 3D models in Solidworks. They are used to improve communication with

the supplier in China and to

illustrate the User Manuals/Part Store.

Representing TES Equipment Supplier – Technician 2006 - 2011

Additional assemblies modeled in Solidworks.

Representing TES Equipment Supplier – Technician 2006 - 2011

This display is used at tradeshows and in the lobby at

TES. The sheet metal is laser cut

and I MIG welded the frame. Blue LED light strips

are encased behind the cutout letters

for the glow effect.

Representing BYU Capstone Project - Drawings 2015-16

Drawings for creating a pitch training softball.

Representing BYU Capstone Project 2015-16

Team logo design possibilities created in Adobe Illustrator.

Modeling BYU MFG 431 – Tool Design

Calculations for most efficient punch pattern, required press tonnage, and size/tolerance of each necessary component to create

the sketched part.

Modeling BYU MFG 431 – Tool Design

Calculations for hole sizes and location pin sizes/tolerances on a

fixture plate.

Prototyping BYU Capstone Project 2015-16

I drilled holes in existing balls and soldered LED lights to batteries and switches to ascertain how well the light could be seen during a

pitch. It was determined that the yellow cover is too distracting and a darker color was chosen.

The final prototype includes a 3D

printed charging base that I modeled in Solidworks and a

team member printed.

Prototyping Sunstone Engineering – Design Engineer 2011 - Present

This is a looks-like/works-like prototype I machined as proof of concept for a pneumatic

tweezer hand piece I designed.

Final Production UnitFinished Prototype with welded sheet metal case

Prototyping Sunstone Engineering – Design Engineer 2011 - Present

This prototype is the result of a design challenge to create the simplest form of a

weld head possible, using minimal components, and minimal assembly

time. The design became so compact that it was converted to be used as a

hand-piece as well.

Prototyping Skill - Machining

Plates for a weld head prototype designed to be used with a XYZ

positioning robot.

Vice we machined for a class project.

Fixture I designed and machined for welding tabs to battery packs.

I have used manual mills and CNC mills to create prototypes and

fixtures.

Simple G-code written for a class

project

Prototyping Skill – Turning (lathe)

Aluminum and nylon hammer designed and turned on a manual lathe

for a class project.

Impact Stud Welder prototype parts

made on a manual lathe.

I wrote the G-code for the pillars of the clock and they were

turned on a CNC Lathe

Prototyping Skill – Sheet Metal Work

Brackets made for an articulating monitor arm and

designed to add another degree of freedom (rotation parallel to

the plane of the monitor)

Prototype Heat Sink for ultra capacitor

cooling.

Drawer Guide Bracket made to replace broken plastic mounts on

kitchen drawer guides.

Sheet metal foot pedal I designed to

be used for actuation of weld heads

Prototyping Skill – MIG Welding

Man Cage created for a forklift. I cut and welded the square tubing for mounting to an

existing skid.

Flip table I made to enable ease of access while mounting assemblies to the encapsulation machine

tables.

Prototyping Skill – Micro Welding

Micro TIG welders deliver pulsed arcs to create spot welds. They can be used for many prototype applications including wire welds, seam welds, battery tab welds, and other fine detail work.

Capacitive Discharge spot welding can be used for thin sheeting, wire welding, battery tabs, medical equipment, roll spot welding, and many other prototyping applications.

Prototyping Skill – Wood Working

Signs my wife and I designed and built.

I use a Dremel to carve figurines out of wood as a hobby

Shipping Crate I built for an encapsulation machine

Stairs I built for my brother’s Great Dane to use.

Pattern made out of MDF for an aluminum sand casting

project.

Experimenting Sunstone Engineering – Design Engineer 2011 - Present

Test strips of copper-to-steel welds used to determine ideal timing settings for electrode retraction, distance, and speed. The experiment used visual indication and

spot size measurements.

Experimenting BYU Capstone Project 2015-16

Test fixture designed to hold the ball in a lathe and allow us to verify revolutions per second measured by gathered and

interpreted accelerometer data.

Experimenting Sunstone Engineering – Design Engineer 2011 - Present

Test used to determine ideal configuration of fins and fans for a resistor prototype

Experimenting BYU STAT 201 – D.O.E. Project

A D.O.E. was performed to

determine what plane shape factors had the

most influence on distance traveled. The

launcher was then used in a different

class for a competition.

Evaluating BYU STAT 201 - Statistics

Evaluation of the gathered launch data suggests which combinations provide the longest distance traveled.

Evaluating BYU MFG 130 – Plane Project

The flight data of several planes is evaluated to determine which launch methods and designs lead to

the least variation in distances traveled.

Evaluating BYU MFG 431 – Tool Design

Analysis of time spent and cost of

goods help predict if a

fixture will save money in the long run, or

become a liability.

Deciding BYU MFG 431 – Tool Design

A decision table assisted me in choosing the best design to meet

the specified criteria.

Deciding BYU MFG 431 – Tool Design

Another fixture design project requiring a

decision table to choose the design with the best

results.

Conveying Sunstone Engineering – Design Engineer 2011 - Present

Excerpts from product assembly manuals for two of the weld heads I

designed.

Conveying Sunstone Engineering – Applications Engineer 2011 - 2013

Email summary of sample test results performed for a

customer. As the applications engineer at Sunstone, I performed

several sample tests per week and sent a similar

summary for each one, with an accompanying video of

the process.

BYU Capstone Project 2015-16Conveying

Summary of information obtained during a phone

conversation with a supplier. The

information was shared with team members to suggest how we should move forward with the casting portion of the

project.

Conveying Sunstone Engineering – Design Engineer 2011 - Present

Summary given to marketing outlining the benefits of a new weld head and how it compares to the old.

Conveying TES Equipment Supplier – Technician 2006 - 2011

Excerpts from a user manual I wrote to be programmed into the HMI of an encapsulation machine.