Tonal
Team | Mechanical Engineer | May 2021 - 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).
Joey Bee (2022) YouTube
- User-Centered Ideation: Addressed a key customer critique of the angle lever unlocking mechanism
- Iteration: Ideated 9 low-fidelity prototypes to explore one-handed operation.
- Prototyping: Developed two high-fidelity prototype for comparison to existing design.
- Testing: Conducted user testing with high-fidelity prototypes for 20 users. 100% of participants preferred one of the new designs.
- Cross-Functional Collaboration: Worked closely with Industrial Designers, manufacturing partners, and hardware team to refine requirements, constraints, and materials.
Tonal Systems Angle Lever User Manual
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.
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 5 low-fidelity 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.
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 3D surface modeling in SolidWorks.