Tonal
Mechanical Engineer - May 2021 to September 2023
I designed and prototyped a new implementation of a lever unlocking mechanism while collaborating closely with Industrial Designers to address a customer critique of the current apparatus.
I also completed tolerance analyses and part drawings via SolidWorks. I presented updates to the hardware team on developments for works-like prototypes and models utilized in user studies.
I am listed on 2 Tonal patents: motor rope containment (09 / 2023) and one-handed arm unlocking mechanism (08 / 2021).
I also completed tolerance analyses and part drawings via SolidWorks. I presented updates to the hardware team on developments for works-like prototypes and models utilized in user studies.
I am listed on 2 Tonal patents: motor rope containment (09 / 2023) and one-handed arm unlocking mechanism (08 / 2021).
Tonal Systems Angle Lever User Manual
Joey Bee (2022) YouTube
I ideated 9 different low-fidelity prototypes to redesign the angle lever unlocking mechanism that allows the arms of a Tonal machine to rotate.
Previously, this mechanism could only be utilized using two hands, but my design allowed for a user to move an arm only utilizing one hand.
Previously, this mechanism could only be utilized using two hands, but my design allowed for a user to move an arm only utilizing one hand.
I am listed on a Tonal patent for a one-handed arm unlocking mechanism (08 / 2021).
I created two sets of high-fidelity prototypes of a one-handed actuating lever to utilize in user testing, comparing both new designs to the previous one-handed design.
100% of participants preferred one of my new designs to the original two-handed version.
100% of participants preferred one of my new designs to the original two-handed version.
As part of this design process, I collaborated with industrial designers to define requirements, constraints, and success criteria for the design.
I generated design concepts through sketching, CAD modeling, and quick physical mock-ups. While prototyping, I applied DFM and DFA principles to ensure my prototypes would be ready to scale into production-ready parts.
Finally, I created detailed technical drawings and Geometric Dimensioning and Tolerancing documentation for each part.
I generated design concepts through sketching, CAD modeling, and quick physical mock-ups. While prototyping, I applied DFM and DFA principles to ensure my prototypes would be ready to scale into production-ready parts.
Finally, I created detailed technical drawings and Geometric Dimensioning and Tolerancing documentation for each part.
Tonal Rope Containment Patent
I created five low-fidelity prototypes of motor rope containment to allow for the rope to spool on a motor while the motor lay horizontal.
Correct spooling needed to be ensured during sudden, jerky movements that resulted in the rope becoming slack along the rope path.
Correct spooling needed to be ensured during sudden, jerky movements that resulted in the rope becoming slack along the rope path.
Although images of this project are covered by NDA, I acted as the only mechanical engineer to lead the initial iterative process for a rope containment mechanism. I developed CAD models and built multiple prototypes to test each design’s functionality, incorporating both additive manufacturing and machined components.
I applied mechanical principles and FEA simulations to validate structural integrity before prototyping. I worked closely with manufacturing partners to refine tolerances and select cost-effective materials.
I applied mechanical principles and FEA simulations to validate structural integrity before prototyping. I worked closely with manufacturing partners to refine tolerances and select cost-effective materials.
As part of my work, I used SLS 3D printers and a machine shop to create low-fidelity prototypes.
I created 3D models of high-fidelity prototypes in SolidWorks that were sent to be fabricated via sheet metal punching, injection molding, and metal casting.
I then collaborated with designers to conduct user research studies with the high-fidelity prototypes I created.
I completed a course with Hawk Ridge Systems for surface modeling in SolidWorks.