Challenge:

Work with a startup to develop an in-vehicle, cloud connected accessory. This product presented a number of challenges, most pressing of which was limiting device maximum internal temperature with high on-board processing power demands. As one of two mechanical engineers on this project, I worked to solve this critical design issue.

Result:

Through iterative machined-metal and DMLS prototypes combined with simulation in Solidworks Flow, we:

• Demonstrated the need for internal forced convection to meet the product requirements

• Explored various architectures for implementing forced convection by fabricating prototypes and conducting testing of design variants to determine which factors affected thermal performance the most

  • These exercises were done with careful attention paid to how feasible designs would be in production given the BOM cost goals of the device

• Collected and analyzed data to determine worst-case conditions for the device

• Designed and fabricated a thermal testbed used by members of the interdisciplinary team to simulate thermal loads and gain insights into device tradeoffs (for instance, restricting processing power in order to reduce maximum power dissipation level)

Skills:

• Solidworks Flow Simulation

• Thermal testing and analysis