2. Matt baum
I want to be a part of designing
the future and conceiving new
ways for us to thrive in the 21st
century. In my work I seek to
combine an understanding of
function and mechanics with an
appreciation of form and beauty
that I have cultivated through my
studies of both engineering and
design. I have developed the
skills to engage in every stage
of product development. I enjoy
design research, product ideation
and sketching, 3D modeling and
rendering, and prototyping and
manufacturing. I am excited and
inspired by the innovation taking
place at the heart of design culture
in areas like renewable energy and
sustainable design, new forms of
transportation and urban planning,
and human-centered products that
connect us to our technology and
to each other. My goal is not merely
to produce and sell more consumer
goods, but to create meaningful
new ways for people to live and
societies to function.
3. Contents
Machine Design
Machined Aluminum Motor Mount
Sheet Metal Motor Mount
Injection Molded Nylon Motor Mount
DVD Return Slot Assembly
Product and Business Design
Modgardens
Prototyping
Heavy Lift Octocopter
3D Printed Impeller
Social Design
Circular Production
Toyota Production Stages
A Nation in Crisis
Resume
4. machine
design
Solidworks 3D Modeling
Design for Manufacture
Mechanical Systems Design
2D Part Drawings
GD&T
motor mount
part design
These motor mounts were
designed in a machine design class
to gain experience with design
for manufacture. Three different
motor mounts were designed
based on the manufacturing
technique: machining, sheet
metal, and injection molding. Each
part model took into account the
manufacturing steps necessary to
produce the design. The assembly
models are toleranced based on
GD&T standards. The motor mount
was designed to fasten the motor
of an archive data storage system
to a flat tray surface to maintain
proper gear alignment. The primary
functions of the motor mount are
to: a) rigidly support the motor shaft
bearing (aligns motor to gears) and
b) incorporate two bearing holding
tabs.
5. machined aluminum
Design
The design has a thick front
surface that is fastened to the shaft
alignment part on either side of
the motor shaft bearing, providing
reliable alignment and stability to
the motor. Two pins on opposite
corners of the part serve to position
the motor mount relative to the
shaft alignment part. The hole and
slot that accommodate these pins
are drilled blind but are designed
with generous depth tolerance.
Fastening the motor mount to the
shaft alignment part using two
screws on the sides of the part
(in addition to the fastener on the
corner flange) avoids the excessive
material removal that would be
required to fabricate flanges for an
entirely top-down assembly.
Manufacturing
The motor mount requires 4
different machining directions and
begins with a 1.5in3 block of solid
aluminum.
Direction 1: Bottom Surface
-Grind surface to 1.117in
-Remove material using a 1/2in
tool
-Mill pin holes using a .093in tool
and drill clearance hole for
fastener using a #5 drill bit
Direction 2: Front Surface
-Drill holes using 5/32in drill bit.
Bore center hole to 0.189in to
accommodate motor shaft
-Mill flange using 5/64in tool
Direction 3: Right Surface
-Grind surface to 1.354in
-Mill flange using 5/64in tool
-Mill corner tab using 5/64in tool
-Drill fastener clearance hole using
#5 drill bit
Direction 4: Back Surface
-Grind surface to 1.437in
-Drill fastener clearance hole using
#5 drill bit
-Mill cutout using 5/64in tool
Analysis
Deflection at load:
δ=(Fl^3)/3EI
h^3=(4Fl^3)/Ebδ
h^3=(4(75lb)(0.478in)^3)/
(10e6psi(0.315in)(0.0118in))
h=0.096in
Bending Stress:
σ=(Fl h/2)/I
σ=6Fl/(bh^2 )
σ=(6(75lb)(0.478in))/((0.315in)
(0.096in))
σ=29638psi
Tensile yield strength of aluminum
6061-T6 is 40,000psi.
Assuming a deflection of 0.0118in
(based on deflection of previous
part) and using a tab thickness of
0.096in resulted in an applied force
of 75lbf and a bending stress of
29,638psi. This is well under the
tensile yield strength of 40,000psi.
Back view of motor mount
6. sheet metal
Design
The chosen design is simple and
efficient, using a minimal amount
of folds and material. Flanges
were created to accommodate
the pins and fasteners, and tabs
were created to hold the bearings
in place. The tabs have a spring-
like form to maximize their ability
to withstand deflection. A vertical
tab of material directly below the
motor shaft bearing serves as a
datum feature and maximizes the
accuracy of the bearing positioning.
A pin and slot on opposite corners
of the part serve to position the
motor mount relative to the shaft
alignment part. Two M2 SHCS
screws are used to fasten the
motor mount to the shaft alignment
part. The part is stamped from a
63mm x 83mm sheet of 16 gauge
(1.651mm) steel and folded into
shape.
Manufacturing
Part begins with a 63mm x 83mm
sheet of 16 gauge steel. Flat
pattern can be nested with spring
tabs overlapping to save material.
1. Stamp or laser cut 63mm x
88mm sheet to form flattened
shape of part.
2. Pierce fastener holes, sized to fit
1/16” dowel pins and M2 fastener
screws.
3. Fold sheet into final form of part
(possible order: a) 2 folds to form
3 base sheets that accommodate
motor b) fold positioning and
securing tabs c) fold spring tabs.
4. Touch up and finishing. Remove
sharp edges.
Analysis
1. The tab structure was simplified
by considering the horizontal
distance of the bent tab to be the
effective length.
2. Initial tab model experienced a
total deflection of 0.254 mm.
3. Goal seek was used to deter-
mine the force needed to match
this assumed deflection.
4. The force needed, 56 lbs,
caused yielding in first iteration of
the spring tab.
5. Length of tabs was adjusted to
reduce deflection.
6. Stress analysis was done on
each individual tab to insure yield-
ing does not occur.
Result: to reduce stress on the
tabs, the tab lengths were adjusted
to produce 34.2 lbs of force with a
total deflection of 0.115mm.
Motor mount installed in assembly
to secure motor shaft and bearings
7. injection molded nylon
Design
The chosen design has a curved
nominal wall that follows the form
of the motor shaft to reduce the
size of the part and the material
used. The tabs that accommodate
the fasteners and hold the
bearings in place are projections
off of the curved nominal wall. The
curved nominal wall and the tab
projections are designed with a
uniform thickness to facilitate an
even injection of material. Fillets
have been added to all of the sharp
corners of the part to make them
easier to fill and avoid high molded-
in stresses. Ribs were incorporated
into the tabs to add support and
rigidity. Two pins are built into the
tabs on opposite corners of the
part to position the motor mount
relative to the shaft alignment part.
Analysis
The deflection of the tab was
computed using a cantilever-end
load condition, and the stress of
the tab was calculated using the
bending stress equation. A tab
deflection clearance of 0.020”
was assumed in order to calculate
the corresponding force needed.
The material chosen for this part
was Nylon. The Nylon has a yield
strength of 12 ksi. The maximum
stress the tabs will have is 10.5 ksi,
so the tabs should not fail.
Manufacturing
The core half of the mold forms
the underside of the curved motor
enclosure and creates the bottom
features of the part (colored in
green), and the cavity half of
the mold forms the top features
(colored in blue). The gate is
located in the center of the top
surface of the curved enclosure,
since this surface is the nominal
wall and the central location of
the gate will allow an even flow of
material into the projected walls.
A side action is used to create
the cutouts for the clearance hole
where the motor mount attaches
to the motor, and for the hole that
accommodates the motor shaft
bearing. The inside surface of the
part has a 2 degree draft angle to
allow a smooth separation of the
core and cavity, and the ribs have a
1 degree draft angle.
Motor mount installed in assembly
to secure motor shaft and bearings
8. DVD REturn slot
assembly
The DVD Kiosk Return Slot is
designed to accept a DVD returned
by the user. It feeds the DVD
back into the machine to a point
where a “picker” can grab it and
file it into the correct location within
the machine. The Return Slot is
mounted on the inside of the overall
DVD Kiosk and is only visible by
its very front slot where the user
returns the DVD. The design uses
a drive system consisting of two
shafts driven by one stepper motor
to move the DVD along its intended
path. Two gates within the Return
Slot interpret signals from the
electronics system that determine
whether or not the DVD will be
accepted into the drive system.
Most of the parts were obtained
from McMaster Carr. Part drawings
are included for the parts that have
been custom designed and must
be manufactured. The assembly
model is toleranced based on
GD&T standards.
DVD return slot assembly
9. Position 1:
The user inserts the edge of a
DVD case inside an injection
molded slot that extends outside
the DVD Kiosk. Four Fairchild
phototransistors detect a valid
DVD case and send a signal to two
solenoids to open the primary gate.
At this point, the DVD case must
be pushed by the user past the first
gate in order to contact the initial
drive roller. The rollers are driven by
a Lin Engineering 4218 High Torque
Stepper Motor, and both rollers are
connected with a belt/gear system.
Position 2:
Once the DVD case is in contact
with the first roller, the DVD is
moved along a sheet metal support
rack past the vicinity of the first
gate. It is constrained horizontally
by cylindrical spacers. At this
point the DVD is detected by two
Agilent HSDL-9100 sensors that
send a signal to all four solenoids
to close the primary gate and
open the secondary gate. Each
gate is detected by two Omron
EE-SX1041 sensors that interpret
when the gate is open or closed.
Position 3:
The DVD case is moved into con-
tact with the second roller which
drives it past the vicinity of the
second gate. Once two final Agilent
sensors detect that the DVD case
is past the vicinity of the second
gate, a signal is sent to the picker
to grab the case from the Return
Slot.
Exploded view of assembly
10. GD&T part drawings of injection molded DVD instertion slot GD&T part drawings of sheet metal support structure
11. product
& business
designProduct Concept Sketching
Solidworks 3D Modeling
Keyshot Rendering
Brand Strategy
Financial Analysis
modgardens
Modgardens was developed in
a product and business design
course that brought together
LMU entrepreneurship and OTIS
design students in an incubator
setting. The project was inspired
by vertical farming, which uses
hydroponic greenhouse technology
to cultivate crops in skyscrapers or
on vertically inclined surfaces. With
over 80% of the world’s population
estimated to live in urban areas by
2050 and limited farmland available
to feed the growing population,
vertical farming could become a
viable option for food production.
Modgardens is a modular
vertical farm and shelving system
designed for wall installation in
urban dwellings. The project
deliverables include a working
prototype, the product functions
and specifications, the engineering
and design, the manufacturing
process and cost, some projected
financials, and the branding and
sales strategy.
13. Modules Price
Hex Garden
Hex Shelf
Half Hex Shelf
Drag and drop modules to create your own modgarden
Size
Harvest
Hex Garden
Hex Garden
Hex Shelf
Hex Shelf
$120
$120
$60
$60
Total $360
28 in x 35 in
2 salads / week
Your Assembly
Move Rotate
Online User Interface Mounting Hardware
Wiring Diagram Components
LED Ultra Violet Light
Plant / Flower / Herb
1/4” Glass Garden Basin
Nutrient Filled Hydro Pearls
Original Sketches
14. The Story
In an increasingly urbanized world, more people
are living in small spaces in cities.
These city dwellers are in search of ways to
make the most of their limited living space.
Small urban living spaces often lack the
presence of plants and trees. Limited light and
space make it difficult to grow indoor plants.
Mission Statement
Modgardens gives customers a way to add
customizable shelving to their walls and produce
fresh and healthy food.
modgardens
Small-scale, modular vertical farms for urban
dwellings.
Includes three modules to offer shelving and a
system to grow plants.
Customers can create their own arrangement to
fit their available space.
Product Specifications
LED flexible strip grow lights
Hydropearls in glass plant bed
Wall mounted or free standing
Lights connect using 2.1x5mm power jacks
Wood frame
Create custom arrangments with 3 different
modules
The Market
Eco-conscious and design savvy customers in
urban dwellings (especially small apartments in
big cities)
Major urban markets:
Los Angeles, San Francisco, Portland, Seattle,
Denver, Chicago, Boston, New York
Product Costs
Competitive Advantage
Competitors do not offer:
Modularity
Shelving space
Wall mounting
Sculptural design
Wood
LED Grow Light
Hydropearls
Glass
Hardware
Electrical
Labor
Total Cost
Retail
$8
$1
$2
$4
$5
$2
$30
$52
$120
Hex Garden Module
Wood
Hardware
Labor
Total Cost
Retail
$9
$5
$15
$29
$60
Hex Shelf Module
Wood
Hardware
Labor
Total Cost
Retail
$6
$5
$10
$21
$40
Hex Shelf Module
Modgardens brand strategy
15. Prototyping
Manual Machining
Soldering
Wiring and Electronics
Use of Power Tools
Rapid Prototyping
Heavy Lift
Octocopter
Quadcopters have been
undergoing a consumer
renaissance as they have
become more affordable and
accessible than ever. The many
potential commercial applications
of quadcopters are still being
explored, in areas such as search
and rescue, structural surveying,
security and law enforcement,
media and broadcoast, and
environmental protection. In early
2012, Congress told the FAA
to write regulations concerning
commercial drones by 2015.
When that happens, businesses
will have clear guidelines for
manufacturing, operating, and
selling drones. This recent surge in
interest in Unmanned Air Vehicles
(UAVs) led the American Society
of Mechanical Engineers (ASME)
to make UAVs the basis for its
2014 student design competition.
The competition scoring system
encouraged copters that could
lift a heavy payload. In order to
maximize the cargo carried and
earn the most possible points
at the competition, the lift of our
propulsion system was optimized.
Our UAV was designed as an X8
octocopter, a craft with two coaxial
propellers on four different arms.
The frame and protective shroud
were constructed by hand, and
the components were chosen
according to our own design.
No preassembled kits or existing
designs were used.
16. Payload carries disproportional
amount of points. The competition
defines the payload as the weight
of cargo plus the weight of the craft
itself. A lightweight craft is therefore
not necessary or ideal.
Limiting factor for maximum
payload is lift possible within
the given size requirement.
Goal is therefore to design for
as much lift as possible within
given dimensions. Lift is primarily
determined by the motor power
and propellor size.
A coaxial design adds a 50%
increase in the copter’s lift. With
two stacked arrangements of four
propellors, the maximum possible
propellor size is 15”. The motors
are chosen to power selected
propellors. The rest of the electrical
components (speed controllers,
batteries, wire gauge) are chosen
based on the motor requirements.
Maximize Weight
Maximize Lift Within
Size Requirement
Coaxial Octocopter
Design
Design Optimization
17. The frame, motors, speed
controllers, and batteries were all
chosen based on the ultimate goal
of maximizing lift. The size of the
frame and propellers were the basis
of the design for the entire system.
The propulsion system consists
of eight propellers, eight motors,
eight electronic speed controllers,
and four batteries. The power
system connects all four five-
cell batteries in parallel and then
distributes this power evenly to
each of the motors. The power is
then distributed to each motor’s
individual speed controller (ESC),
which receives a signal input from
the flight controller and regulates
the supplied power to its motor.
The signal side of the control
system runs through the flight
controller. The control board
receives signals on four channels
from the receiver (RX) which is sent
to it from the transmitter (TX). It
then processes these directional
controls of throttle (CH1), roll (CH2),
pitch (CH3), and yaw (CH4) along
with readings from its instruments.
Unique signals are then sent to
each of the eight ESCs through
eight outputs on the control board,
supplying the appropriate amount
of power to the motors in order to
carry out the controls received from
the transmitter.
The control system is run on
MultiWii V2.3 code, open source
code available online that supports
a number of different copter
configurations, from simple
tricopters to coaxial octocopters.
This Arduino code was edited in
order to properly control the motor
configuration and components of
the UAV, and then loaded onto to
the control board through a micro
USB connection. The control board
processes and settings can be
viewed and adjusted through a
graphical user interface (GUI) on a
laptop. Through this interface, it is
possible to monitor and calibrate
the copter’s instruments, set
auxiliary channel controls, select
flight modes, and adjust PID
settings, which govern the self-
stabilization of the copter.
18. 3D printed impeller
An impeller was designed for
optimum performance based
on fluid dynamics theory. A 40
degree backswept flow exit angle,
the maximum blade height, and
required outside diameter were
given. The flow inlet angle, inner
diameter, and number of blades
were determined. The chosen
design was then modeled in
Solidworks and printed on a
Stratasys rapid prototyping
machine. The 3D printed model
was tested in a blower, and
the experimental results were
compared to theoretical data on
impeller performance.
19. Social
design
Idea Webs
Product Life Cycle
Social Context of Design
I am passionate about using design
to create positive changes in the
way people live and societies
function. I have put considerable
thought into the role of design in
the modern world and what needs
can be addressed by designers,
including transportation, food
production, urban planning, and
alternative energy technologies. It
is important that as designers we
ask: Are the things that we design
really making an effect and making
change? For much of design no
longer operates with the good of
the consumer in mind. Its goal is to
produce and sell more consumer
goods, not to make people happier,
safer, more comfortable, or more
efficient.
In the diagrams that follow, I
explore the ways in which we
produce and how production
can be made more sustainable;
the impact of the different stages
necessary to bring a product to
market; and some of the major
social issues we are currently facing
in the United States.
21. A nation in crisisMajor Social and Political Issues in the U.S.
22. Matt baum
Loyola Marymount University, Los Angeles, California
Bachelor of Science, Mechanical Engineering
GPA: 3.3
LMU Honors Program and Presidential Scholar
SKills
Solidworks Modeling
Keyshot Rendering
Design for Manufacture
Technical Drawings (GD&T)
Product Mockups
Rapid Prototyping
Manual Machining
Soldering
Design Research
Concept Sketching
Illustrator
Photoshop
Relevant coursework
Product and Business Design
Machine Design
Computer Aided Design
History of Design
Social Design
Material Selection in Design
Mechanics and Materials
Fluid Dynamics
Statics and Dynamics
Thermodynamics
Circuits
Environmental Science
830 Cheltenham Road / Santa Barbara, CA 93105 / 805-448-9905 / mattwbaum@gmail.com
education
Work experience
Lifestyle Design, Santa Barbara, CA - Industrial Design Intern
Lifestyle Design is a design agency that offers strategic branding, strategy, product
design and packaging design services. While I was interning with Lifestyle Design
I participated in the reconception of the brand strategy for one of their major
clients (House of Marley), helped produce new graphics and renderings for a line
of headphones (House of Marley), and helped conceive and model the form of a
new portable speaker (Respectify). I gained experience with 2D ideation on paper
and in Illustrator and 3D modeling and rendering in Solidworks and Keyshot, and
learned about design for manufacture, product pricing, marketing strategy, and
brand strategy. My experience at Lifestyle Design helped me to understand product
design and strategy. It made me more capable to work alongside designers as a
mechanical engineer.
Neal Feay Company, Santa Barbara, CA - Engineering Intern
Neal Feay is an aluminum manufacturing company that designs and manufactures
high-end audio equipment and furniture. While at Neal Feay I gained exposure to
the entire production process of a product: beginning with rough pencil sketches
and evolving into a dimensioned CAD model, the interaction between the engineers
and the machinists to correctly machine the part using CNC routers, finishing the
part (sanding and coloring), and shipping the parts to customers. This experience
gave me a clearer picture of the context in which engineers and designers work as
it relates to the rest of the production process.
Summer 2013
Summer 2012