stanley mayer portfolio
DESCRIPTION
Presentation of accomplishments that reduced labor content, reduced part cost, made products safer and longer lasting, increased profits and reduced tooling costs. Using design for three different ultrasonic cleaners was streamlined. Simplifying assembly, reducing parts in inventory, and taking labor out of the process. Design sheet metal assemblies for low volume production and still provide a rich user experience for the product. Redesign a nose piece for a dental curing lamp to reduce part count, reduce assembly labor, and prevent the dentist from burning himself or the patient. Thru reducing liability for the company. Design a custom die-cut label to be used in a bar-code printer to allow 1,800 SKUs to be generated with one label. Develop all aspects of the process from locating a vendor for the label to training floo9r personal in the use of the system.TRANSCRIPT
Stanley E. Mayer
Portfolio
Design for AssemblyUltrasonic Cleaner
This design required working closely with the Industrial Designer to maintain the look and feel desired for the product.
Only 5 screws are used in this assembly: • 2 for EMI filter• 1 on cable clamp• 2 fasten upper and lower
housing together.
The PCB is clamped between the upper and lower housing. The tank is bonded in place with RTV, sealing the edge to prevent water ingress. The custom-designed white LCP holder for the circular transformer core allows the transformer to be fabricated quickly and placed on the PCB easily.
Design for AssemblyUltrasonic Cleaner
This design led to a significant savings in assembly time over the previous design.
The part was designed to eliminate any cams in the mold, lowering the cost to produce and maintain the mold.
Ferrite and winding, in the lower left corner, are held by snap features integrated into the injection-molded base. The molded features of the base and one screw hold the printed circuit board.
Design for AssemblyGutta Purcha Heater
Redesign of unit decreased assembly time. Replacing the fixed cord with an IEC connector allowed for sale of the unit in many countries without additional SKUs.
Only 2 threaded standoffs and 1 screw required to hold the unit together. Terminal blocks reduce wiring time.
First standoff is screwed into the base of the cylindrical aluminum heater block. The second is screwed into the first and holds the PCB in place. A screw secures the bottom cover in place.
Sheet Metal DesignLight fixture Hot Aiming Assembly
Designed for low-volume production, the assembly contains:• pop rivet (4)• wave washer (2)• e ring (2) • injection molded part (2)• die cast pinion (2)• die cast rack (2)
The sheet metal parts are laser cut and formed on a press brake. The rack gear is staked in place using the hollow pins on the back. The staking tool, air press selection, and operator training were all included in the scope of the project.
Sheet MetalBarndoors for Light fixture
The redesign improved performance. Through the addition of the spring and the flex-top hex nut the doors to hold their position properly through thousands of adjustments.
The use of stamping tools reduced the manufacturing cost by 75%, increasing sales and doubling profits.
Sheet MetalAutoclave Dental Cassette
This sheet metal dental cassette was designed for production in China, using transfer-style stamping dies. The latch and spring arms secure the instruments during the process of insertion into the autoclave bag and the sterilization cycle. Beam calculations were required for both the spring arms and latch to ensure that parts did not take a permanent set. The latch detail is especially critical to the proper operation of the unit.
Injection MoldingElectrosurgical Tip
Innovative redesign added the female threaded ferrule implementing rotation of the electrode sheath. This gave the dentist ability to turn the tip easily, gaining more control of the instrument during surgery.
The addition of rotation was accomplished by using a Hypertac â
low force connector. The male connector is soldered to a copper tube and that assembly is then insert molded into the electrode sheath.
Electrode sheath can be sterilized in an autoclave repeatedly. Molded from liquid crystal polymer a free flowing and highly heat— and chemical—resistance plastic.
This 2-piece handle is ultrasonically welded together with the freely rotating female threaded ferrule retained in-between. Electrical wiring including 2 LEDs inside handle.
The injection molder included the electrode sheath in their sales sheet showcasing capabilities and technical expertise.
Project included part design, coordination with injection molder, selection of ultrasonic welder, ultrasonic horn design, and set-up of equipment in factory.
Heat TransferDental Curing Lamp Nosepiece
Original design Improper air flow around spun metal part lead to over heating.• Overheating shortened lamp life.• High temperatures on the exterior put dentist and
patient at risk of being burned.• Many parts and small screw made assembly difficult.• Lens cracking common during heating and cooling of
operation.
Re-design.• Ribs on die casting allow dissipation of heat
into airflow.• Reduced temperature led to increased lamp
life.• Lower exterior temperatures remove risk of
burns to dentist and patient.• Tool-less assembly.• Custom molded silicone lens holder
prevented breakage of dichroic lens.
LabelingCustom Bar Code Labels
One custom die cut label. Printed in house on a thermal transfer printer. Hundreds of unique SKUs created. Label seals the package and provides tamper evidence. Project included vendor selection, printer selection, printer programing and training of floor personal.
