Case Studies
Selected examples of custom design, reverse engineering, and functional prototyping.
Lightweight Ladder Support Bracket - Load-Validated Design
Lightweight ladder support bracket designed to meet a defined load requirement while minimizing material. The part was modeled in CAD, evaluated under a distributed load in simulation, and refined to improve strength-to-weight performance. Final design was fabricated and validated in real-world use.
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Replacement Bed Foot - Reverse Engineered & Load-Validated
Replacement bed foot designed after the original component failed. The part was reverse engineered to match fit and interface geometry, then evaluated under expected loading to ensure adequate strength. Final part was fabricated and installed with no issues in service.
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Headlight Adjuster - Reverse Engineered & Tested
Custom replacement headlight adjustment component created after the original part failed. The geometry was reverse engineered to restore proper adjustment and fit within the existing assembly. The part has been in service for months with no functional issues.
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Headlamp - Reverse Engineered & Tested
Reverse-engineered headlamp enclosure recreated to capture intricate geometry and fine functional details. The original part was measured and modeled in CAD, critical interfaces were preserved, and the design was prepared for resin printing. The final part was printed in high-resolution resin and validated for fit, finish, and function.
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Additional Projects
A collection of smaller projects that highlight my CAD, Reverse Engineering, and 3D Printing capabilities.
Vacuum Crevice Tool
Custom vacuum attachment designed to access tight crevices.
DeWalt Battery Wall Mount
Wall-mounted battery holder designed for secure storage and quick access.
Vacuum Sander Attachment
Attachment designed to quickly attach vacuum hose to sander for dust collection.
Oil Filter Socket
Oil filter socket designed and printed to replace an off-the-shelf tool that did not fit the application.
Cabinet Drawer Guide
Replacement guide designed and printed for worn dovetail drawer slide.
Light Globe
Replacement light globe reverse engineered and printed out of clear resin.
Dirt Bike Piston
Reverse engineered piston from an old dirt bike to create an accurate CAD model for analysis.
Machinable Dirt Bike Cylinder Head
Reverse engineered cylinder head from an old dirt bike and modified for machinability. Required splitting into two pieces to accommodate the coolant passages.
Shower Knob
Replacement shower knob designed and printed to achieve custom look not available off-the-shelf.
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