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Portfolio of My Projects
by Steven Worden
November 2015
Manufacturing
Mechanical
Engineering
Industrial
Design
I have a blended background balanced in mechanical engineering, industrial design, and manufacturing.
Each of my backgrounds augment and enhance the other disciplines and skills. For example: a thorough background
in manufacturing improves ID and ME “DFX” by considering the most cost effective process to achieve the goal. A
strong understanding of ID intent and ability to think, visualize, and rapidly sketch in 3D aids in exploring optimal
designs, or communicating ideas to management, ME, or manufacturing. My strong mechanical background and
experience allows me to be considering the implications of any concept or design solution ensuring they are sound
and manufacturable.
Because most of my career was on the consulting side I have a more extensive portfolio than most design or
engineering studios. I have worked with many companies, across a diverse range of products, and processes.
I have lead or managed most of the projects I have worked on.
I have taken most of my products from a spark of an idea through to production.
Barnes & Noble Consumer Products
Nook GlowLight Plus
Barnes & Noble Consumer Products
Nook Charging Dock Inductive Charger 1 Inductive Charger 2 Adjustable Reading Stand Nook Audio OE250 Nook Audio OE500 HD TV Adapter Kit Nook Audio Headphone
Nook Audio IE250 Nook Audio IE500 Nook Audio Speaker Exploded Nook Audio BT500 Speaker Nook Audio BT500 Speaker Nook Bluetooth Keyboard Nook Stylii Nook Color Charge Cable
Book Like Covers Lightweight Smart Covers Cover/Stands Developed Fits for Devices Kick Stand Cover Ergonomic Keyboard USB-A Adapter Dual Port Car Charger
TPU Pen Clip Development Device to Cover Attachment HD Tasume Cover/Stand Lincoln Project Nook Travel Power Pack Nook GlowLight Clip Cover Pen Clip with Kickstand Bluetooth Remote
Nook Audio BT 500 Bluetooth Speaker
Barnes & Noble Consumer Products
Lincoln Project
Consumer Products
Skeet Ultralight Catamaran Converts to Bike-able Trailer Smoke Testing CAD Mass Modeling Apple: G4 Chassis Extruded TaskLight Warner World POP
Braun “Tadpole” Dry Sub Logitech: Concepts Logitech: 4000 ProBase Etak: Auto Navigation 1983 Plantronics: Extendable Arm Plantronics: Extendable Arm Coulthad Identity: Spin Logitech: Case for PSP PlayGear
Logitech: QuickCam 4000 Logitech: QuickCam 4000 Logitech: ProBase 4000 Logitech: QuickCam 4000 Commodore Amiga: Amiga 2000 ZeeWaves: Directional WiFi Coulthad Identity: Jack Anchor
Artelonics Modular Computer ‘82 Marketron: Computer Palm: Palm One Dock Arneson Pool Sweep II Arneson Pool Sweep II Arneson Pool Sweep II Idea for Adjustment Spool FEA for Adjustment Spool
Apple G4 “MDD” Computer Apple Mac Classic II
Architectural Exploration G4 Spacial Modeling in CAD Apple G4 Handle FEA Apple G4 Prototype Chassis Production Apple G4 Production Mac Classic II 1 Pc Chassis Design
Speed Way DrillZK CellTest Logitech PSP PlayGear
Logitech: Concept for USB Camera that folds into a Pen 1982 design for a chuck-less Hand Drill with hydraulic gear reduction, levels, and drill bit storage in handle. Sony PSP game cartridge secure and eject solutions
ZK CellTest: Low Cost Hand Held Mobile Cell Field Tester
Symbol MC3000 Mobile Handheld Computer DataCard Terminal
Hand Held Point of Purchase Terminals
Medical Products
Game Ready: Cold Compression HP: Mass Selective Detector HP: Mass Selective Reactor MID Labs: MVS Family Varian: Ergonomic Study Varian: Head Support Exploded Varian: Head Support System Varian: Head Support System
Game Ready: Exploded CAD View Veeco: Electron Microscope Integrated Biosystems Freeze/Thaw System Lusora: Lisa Pendant Lusora: Lisa Camera Switch Lusora: Lisa Motion Detector Allux: Airway Mucosa Treatment
Resonex: Control Console Resonex: MRI mockup Resonex: MRI at show Imatron: CAT Scanner Model Imatron: CAT Scanner Applied Bio’: Electrophoresis Siemens: Flat Panel Conversion Ensosonics: Ultrasound
Thoratec: Heart Pump Adapter Thoratec: Heart Pump Adapter Thoratec: Heart Pump Adapter Imatron: CAT Scanner Cutaway Sylvan Source: M600 UltraClean Sylvan Source: M600 UltraClean Omnicell: Secure Medical Cart Omnicell: Secure Medical Cart
Sun Fire Family Model Sun Fire X4200 Sun Fire X4100 K3 Netrax
SunFire Family ID Model and Transport Case Sun Fire X4200 ME Product Development Sun Fire X4100 ME Product Development Sun Fire K3 Netrax ME Product Development
Industrial Products
Amonix: 7700 MagaModule CPV Silicone Solutions 3wk ID to Show Credence Syst: Diamond 10 Credence Syst: Diamond 10 IntegriNautics: AutoFarm GPS Quickturn: Silicone Simulator Quickturn: Silicone Simulator Towa/Intercon: Chip Sigulation
Precision Echo: Special Effects WJ: MCI Test Exploded Measurex: End Bell Measurex: End Bell Service Honneywell/Measurex Electroglas: Mock-up Electroglas: 4085X Prober Exploration Systems: Oil Maps
NASA: Mobile Telepresence Adept: Transport Cart Adept: Thermal Burn-In Adept: Vision Controller Diasonics: Spectra Ultrasound WJ: MCI Mobile Test Head WJ: MCI Mobile Test Head Optimem: Laser Cartridge
Spectra Physics: SpecraSystem Spectra Physics: Pump Grace Vydak MODcol Grace Vydak MODcol Rational Machines: Mainframe Precision Echo: Special Effects IMI: Eprom Programer IMI: Eprom Programer
Industrial Products
Adate: Test System Adate: Test System Bud Industries: E-Furniture Gabilan: Welder Ergonomics Gabilan: Robotic Welder Gabilan: Robotic Welder Navy/Marine: Night Vision Trainer Navy/Marine: Night Vision Trainer
FETtest: Mixes Signal Testing Xen Systems: Twin Monitor Xen Systems: Twin Monitor NetApp: Flash Storage Bd Polycom: Media Cart Polycom: Media Cart Amonix: 7700 MagaModule CPV Amonix: 7700 MagaModule CPV
Amonix: 7700 MagaModule CPV Amonix: 7700 MagaModule CPV NetApp: Accelerator Bd Cisco: CT3210 Telepresence Cisco: Telepresence Frame Cisco: Telepresence Frames Cisco: Telepresence Frames Cisco: Monitor Adjustment
Cisco: Frame Shock & Vibe Cisco: Telepresence Tables Cisco: Hanging Monitors Cisco: Cameras Cisco: Telepresence Frame NetFRAME: NF400 Mainframe NetFRAME: NF200 Mainframe Cisco: Arctic II Hot Swap PS 13.Kw
Rack Mount Products
Andes Industries: A500 FIPS Force 10: E-Series Core Router HP: Integrity RX6600 Server HP: Integrity RX6600 Server HP: Integrity RX6600 Server HP: Integrity RX3600 Server HP: Integrity RX3600 Server GigaLabs: 32X32 HIPPI Switch
Brocade: 2U Fabric Brocade: Concept BrightLink: Optical Switch BrightLink: Optical Switch Dell: PowerEdge 1550 Server TeraBurst: Optical Server Family TeraBurst: Optical Server TeraBurst: Optical Server
Nortel Networks: VoiP Expansion Iron Systems: Front Graphics Maxxan Graphic ID Echo: Bridge Video Storage Pillar Data Systems: Family NetApp: FAS3140 Switch NetApp: Next Generation Cabinet
Hitachi Data System: Bezels Hitachi Data Systems Decru: 2U DataFort Decru: LKM500 Prototypes Decru: “Blade” White Board Superconducting Technologies Cisco: Catalyst 2900 Family First Virtual Corporation
Rack Mount
Rackable: Drive Shelf Rackable: Drive Shelf Rackable: Drive Shelf Send Mail: eAuthority Switch Iron Systems: 4 slot Chassis Coyote Point: Backlit Metal Logo InfoBlox: Network Appliance Packet Engines: Giga Switch
Iron Systems: 1U NetAppliance NetApp: DS4243 Storage Shelf NetApp: DS4243 Storage Shelf NetApp: DS4243 Storage Shelf Cisco: CRS1-16 Chassis Cisco: CRS1-16 Core Router Cisco: CRS1-16 Core Router Cisco: CRS1-16 Chassis
CacheLogic: CasheSwitch 320 Harmonic: ProStream 9100 Harmonic: Light Bar Tests NetApp: Drive Tray NetApp: Rapid Proto Cisco: CRS1-16 Structure Cisco: CRS1-16 Structure Cisco: CRS1-16 Acoustic Test
Decru: 1U DataFort HP: RX6600 Mock-up HP: RX6600 Mock-up HP: Integrity RX6600 Server HP: Integrity RX3600 Server HP: Integrity RX6600 Server HP: Integrity RX6600 Server Cisco: CRS1-16 Fan Tray
Cisco CRS Core Router Cooling & Power Distribution
TOP
PLIM
T1
TOP
LC
T1
TOP
PLIM
T2
TOP
LC
T2
TOP
LC
T3
TOP
PLIM
M1
TOP
PLIM
M2
TOP
PLIM
B1
TOP
PLIM
B2
TOP
LC
M1
TOP
LC
M2
TOP
LC
M3
TOP
LC
B1
TOP
LC
B2
TOP
LC
B3
BTM
PLIM
T1
BTM
LC
T1
BTM
PLIM
T2
BTM
LC
T2
BTM
LC
T3
BTM
PLIM
M1
BTM
PLIM
M2
BTM
PLIM
B1
BTM
PLIM
B2
BTM
LC
M1
BTM
LC
M2
BTM
LC
M3
BTM
LC
B1
BTM
LC
B2
BTM
LC
B3
Viewed from the side with airflow regions
along the depth of card slot
Intake Grill
Exhaust Grill
© 2006-2008Global Reach Now2
Summary of all runs
Vavni&Input&+&Mechanical Run&#1 Run&#2 Run&#3 Run&#4 Run&#4&Add
Purpose Baseline(1st(design
Inprove(structure(and(
reduce(parts,(weight(7(
some(adds(and(
deletes
Inprove(structure(and(
reduce(parts,(weight(7(
some(adds(and(
deletes
Reduce(Side(Structure(
Thickness(due(to(card(
cage(got(wider
Additional(and(
historical(data
Wall(thickness 1.5" 1.4"
Vert.(Beam(Thk .059" .075"
Billets Yes Removed
T7Bars No Added
Load(Transfer(Bars 1.5"H(x(.080"(Thk 2.0"H(x(.100"(Thk
2.0"H(x(.120"(Thk(+(
plates
Base(Channels No Yes Removed
Cross(Bars Rod/Tube Alu(Solid(Rod
CAD(File(Input(Name
MASTER_VE_ASM_19FEB_
B.zip
CAD(File(Input((Date
K&H&Results&Output
Start(Date
Report(Date 297Jan 187Feb 227Feb 17Mar 47Mar
Cost
Report(File kha_vavni_01.pdf((( kha2.pdf kha3.pdf kha4.pdf kha4add.pdf
Pages 59 28 30 28 6
Title
"CRS1(Chassis(
Chassis(Redesign" "Design(Mod(1" "Design(Mod(2" "Design(Mod(3" "Design(Mod(3"
Results(/(Stress(Levels
Some(weaknesses(
found(in(card(cage(
and(load(transfer(
bars
Better,(lighter,(needs(
improvement Better(still
Concern(over(cross(
beam(rods
Displacements:
Top(Chassis((1%) 0.624 0.2601 0.2461 0.305 0.705
Mid(Chassis((1%) 0.238 0.1031 0.1032 0.144
Relative 2.05 0.85 0.81 1.00 2.31
Cisco CRS Core Router

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Portfolio of Projects by Steven Worden Nov 2015

  • 1. Portfolio of My Projects by Steven Worden November 2015
  • 2. Manufacturing Mechanical Engineering Industrial Design I have a blended background balanced in mechanical engineering, industrial design, and manufacturing. Each of my backgrounds augment and enhance the other disciplines and skills. For example: a thorough background in manufacturing improves ID and ME “DFX” by considering the most cost effective process to achieve the goal. A strong understanding of ID intent and ability to think, visualize, and rapidly sketch in 3D aids in exploring optimal designs, or communicating ideas to management, ME, or manufacturing. My strong mechanical background and experience allows me to be considering the implications of any concept or design solution ensuring they are sound and manufacturable. Because most of my career was on the consulting side I have a more extensive portfolio than most design or engineering studios. I have worked with many companies, across a diverse range of products, and processes. I have lead or managed most of the projects I have worked on. I have taken most of my products from a spark of an idea through to production.
  • 3. Barnes & Noble Consumer Products Nook GlowLight Plus
  • 4. Barnes & Noble Consumer Products Nook Charging Dock Inductive Charger 1 Inductive Charger 2 Adjustable Reading Stand Nook Audio OE250 Nook Audio OE500 HD TV Adapter Kit Nook Audio Headphone Nook Audio IE250 Nook Audio IE500 Nook Audio Speaker Exploded Nook Audio BT500 Speaker Nook Audio BT500 Speaker Nook Bluetooth Keyboard Nook Stylii Nook Color Charge Cable Book Like Covers Lightweight Smart Covers Cover/Stands Developed Fits for Devices Kick Stand Cover Ergonomic Keyboard USB-A Adapter Dual Port Car Charger TPU Pen Clip Development Device to Cover Attachment HD Tasume Cover/Stand Lincoln Project Nook Travel Power Pack Nook GlowLight Clip Cover Pen Clip with Kickstand Bluetooth Remote
  • 5. Nook Audio BT 500 Bluetooth Speaker
  • 6. Barnes & Noble Consumer Products Lincoln Project
  • 7. Consumer Products Skeet Ultralight Catamaran Converts to Bike-able Trailer Smoke Testing CAD Mass Modeling Apple: G4 Chassis Extruded TaskLight Warner World POP Braun “Tadpole” Dry Sub Logitech: Concepts Logitech: 4000 ProBase Etak: Auto Navigation 1983 Plantronics: Extendable Arm Plantronics: Extendable Arm Coulthad Identity: Spin Logitech: Case for PSP PlayGear Logitech: QuickCam 4000 Logitech: QuickCam 4000 Logitech: ProBase 4000 Logitech: QuickCam 4000 Commodore Amiga: Amiga 2000 ZeeWaves: Directional WiFi Coulthad Identity: Jack Anchor Artelonics Modular Computer ‘82 Marketron: Computer Palm: Palm One Dock Arneson Pool Sweep II Arneson Pool Sweep II Arneson Pool Sweep II Idea for Adjustment Spool FEA for Adjustment Spool
  • 8. Apple G4 “MDD” Computer Apple Mac Classic II Architectural Exploration G4 Spacial Modeling in CAD Apple G4 Handle FEA Apple G4 Prototype Chassis Production Apple G4 Production Mac Classic II 1 Pc Chassis Design
  • 9. Speed Way DrillZK CellTest Logitech PSP PlayGear Logitech: Concept for USB Camera that folds into a Pen 1982 design for a chuck-less Hand Drill with hydraulic gear reduction, levels, and drill bit storage in handle. Sony PSP game cartridge secure and eject solutions ZK CellTest: Low Cost Hand Held Mobile Cell Field Tester
  • 10. Symbol MC3000 Mobile Handheld Computer DataCard Terminal Hand Held Point of Purchase Terminals
  • 11. Medical Products Game Ready: Cold Compression HP: Mass Selective Detector HP: Mass Selective Reactor MID Labs: MVS Family Varian: Ergonomic Study Varian: Head Support Exploded Varian: Head Support System Varian: Head Support System Game Ready: Exploded CAD View Veeco: Electron Microscope Integrated Biosystems Freeze/Thaw System Lusora: Lisa Pendant Lusora: Lisa Camera Switch Lusora: Lisa Motion Detector Allux: Airway Mucosa Treatment Resonex: Control Console Resonex: MRI mockup Resonex: MRI at show Imatron: CAT Scanner Model Imatron: CAT Scanner Applied Bio’: Electrophoresis Siemens: Flat Panel Conversion Ensosonics: Ultrasound Thoratec: Heart Pump Adapter Thoratec: Heart Pump Adapter Thoratec: Heart Pump Adapter Imatron: CAT Scanner Cutaway Sylvan Source: M600 UltraClean Sylvan Source: M600 UltraClean Omnicell: Secure Medical Cart Omnicell: Secure Medical Cart
  • 12. Sun Fire Family Model Sun Fire X4200 Sun Fire X4100 K3 Netrax SunFire Family ID Model and Transport Case Sun Fire X4200 ME Product Development Sun Fire X4100 ME Product Development Sun Fire K3 Netrax ME Product Development
  • 13. Industrial Products Amonix: 7700 MagaModule CPV Silicone Solutions 3wk ID to Show Credence Syst: Diamond 10 Credence Syst: Diamond 10 IntegriNautics: AutoFarm GPS Quickturn: Silicone Simulator Quickturn: Silicone Simulator Towa/Intercon: Chip Sigulation Precision Echo: Special Effects WJ: MCI Test Exploded Measurex: End Bell Measurex: End Bell Service Honneywell/Measurex Electroglas: Mock-up Electroglas: 4085X Prober Exploration Systems: Oil Maps NASA: Mobile Telepresence Adept: Transport Cart Adept: Thermal Burn-In Adept: Vision Controller Diasonics: Spectra Ultrasound WJ: MCI Mobile Test Head WJ: MCI Mobile Test Head Optimem: Laser Cartridge Spectra Physics: SpecraSystem Spectra Physics: Pump Grace Vydak MODcol Grace Vydak MODcol Rational Machines: Mainframe Precision Echo: Special Effects IMI: Eprom Programer IMI: Eprom Programer
  • 14. Industrial Products Adate: Test System Adate: Test System Bud Industries: E-Furniture Gabilan: Welder Ergonomics Gabilan: Robotic Welder Gabilan: Robotic Welder Navy/Marine: Night Vision Trainer Navy/Marine: Night Vision Trainer FETtest: Mixes Signal Testing Xen Systems: Twin Monitor Xen Systems: Twin Monitor NetApp: Flash Storage Bd Polycom: Media Cart Polycom: Media Cart Amonix: 7700 MagaModule CPV Amonix: 7700 MagaModule CPV Amonix: 7700 MagaModule CPV Amonix: 7700 MagaModule CPV NetApp: Accelerator Bd Cisco: CT3210 Telepresence Cisco: Telepresence Frame Cisco: Telepresence Frames Cisco: Telepresence Frames Cisco: Monitor Adjustment Cisco: Frame Shock & Vibe Cisco: Telepresence Tables Cisco: Hanging Monitors Cisco: Cameras Cisco: Telepresence Frame NetFRAME: NF400 Mainframe NetFRAME: NF200 Mainframe Cisco: Arctic II Hot Swap PS 13.Kw
  • 15. Rack Mount Products Andes Industries: A500 FIPS Force 10: E-Series Core Router HP: Integrity RX6600 Server HP: Integrity RX6600 Server HP: Integrity RX6600 Server HP: Integrity RX3600 Server HP: Integrity RX3600 Server GigaLabs: 32X32 HIPPI Switch Brocade: 2U Fabric Brocade: Concept BrightLink: Optical Switch BrightLink: Optical Switch Dell: PowerEdge 1550 Server TeraBurst: Optical Server Family TeraBurst: Optical Server TeraBurst: Optical Server Nortel Networks: VoiP Expansion Iron Systems: Front Graphics Maxxan Graphic ID Echo: Bridge Video Storage Pillar Data Systems: Family NetApp: FAS3140 Switch NetApp: Next Generation Cabinet Hitachi Data System: Bezels Hitachi Data Systems Decru: 2U DataFort Decru: LKM500 Prototypes Decru: “Blade” White Board Superconducting Technologies Cisco: Catalyst 2900 Family First Virtual Corporation
  • 16. Rack Mount Rackable: Drive Shelf Rackable: Drive Shelf Rackable: Drive Shelf Send Mail: eAuthority Switch Iron Systems: 4 slot Chassis Coyote Point: Backlit Metal Logo InfoBlox: Network Appliance Packet Engines: Giga Switch Iron Systems: 1U NetAppliance NetApp: DS4243 Storage Shelf NetApp: DS4243 Storage Shelf NetApp: DS4243 Storage Shelf Cisco: CRS1-16 Chassis Cisco: CRS1-16 Core Router Cisco: CRS1-16 Core Router Cisco: CRS1-16 Chassis CacheLogic: CasheSwitch 320 Harmonic: ProStream 9100 Harmonic: Light Bar Tests NetApp: Drive Tray NetApp: Rapid Proto Cisco: CRS1-16 Structure Cisco: CRS1-16 Structure Cisco: CRS1-16 Acoustic Test Decru: 1U DataFort HP: RX6600 Mock-up HP: RX6600 Mock-up HP: Integrity RX6600 Server HP: Integrity RX3600 Server HP: Integrity RX6600 Server HP: Integrity RX6600 Server Cisco: CRS1-16 Fan Tray
  • 17. Cisco CRS Core Router Cooling & Power Distribution
  • 18. TOP PLIM T1 TOP LC T1 TOP PLIM T2 TOP LC T2 TOP LC T3 TOP PLIM M1 TOP PLIM M2 TOP PLIM B1 TOP PLIM B2 TOP LC M1 TOP LC M2 TOP LC M3 TOP LC B1 TOP LC B2 TOP LC B3 BTM PLIM T1 BTM LC T1 BTM PLIM T2 BTM LC T2 BTM LC T3 BTM PLIM M1 BTM PLIM M2 BTM PLIM B1 BTM PLIM B2 BTM LC M1 BTM LC M2 BTM LC M3 BTM LC B1 BTM LC B2 BTM LC B3 Viewed from the side with airflow regions along the depth of card slot Intake Grill Exhaust Grill © 2006-2008Global Reach Now2 Summary of all runs Vavni&Input&+&Mechanical Run&#1 Run&#2 Run&#3 Run&#4 Run&#4&Add Purpose Baseline(1st(design Inprove(structure(and( reduce(parts,(weight(7( some(adds(and( deletes Inprove(structure(and( reduce(parts,(weight(7( some(adds(and( deletes Reduce(Side(Structure( Thickness(due(to(card( cage(got(wider Additional(and( historical(data Wall(thickness 1.5" 1.4" Vert.(Beam(Thk .059" .075" Billets Yes Removed T7Bars No Added Load(Transfer(Bars 1.5"H(x(.080"(Thk 2.0"H(x(.100"(Thk 2.0"H(x(.120"(Thk(+( plates Base(Channels No Yes Removed Cross(Bars Rod/Tube Alu(Solid(Rod CAD(File(Input(Name MASTER_VE_ASM_19FEB_ B.zip CAD(File(Input((Date K&H&Results&Output Start(Date Report(Date 297Jan 187Feb 227Feb 17Mar 47Mar Cost Report(File kha_vavni_01.pdf((( kha2.pdf kha3.pdf kha4.pdf kha4add.pdf Pages 59 28 30 28 6 Title "CRS1(Chassis( Chassis(Redesign" "Design(Mod(1" "Design(Mod(2" "Design(Mod(3" "Design(Mod(3" Results(/(Stress(Levels Some(weaknesses( found(in(card(cage( and(load(transfer( bars Better,(lighter,(needs( improvement Better(still Concern(over(cross( beam(rods Displacements: Top(Chassis((1%) 0.624 0.2601 0.2461 0.305 0.705 Mid(Chassis((1%) 0.238 0.1031 0.1032 0.144 Relative 2.05 0.85 0.81 1.00 2.31 Cisco CRS Core Router