Mechanical and Mechatronic Product Design
Complete mechatronic products from mechanical enclosure to embedded electronics — structural design, custom PCB development, and embedded firmware in a single deliverable.Capabilities cover sensor and actuator integration, multi-rail power electronics, stepper and servo motor control, and programmable light sequencing. 3D printing used for both prototyping and end-use production.Firmware development on AVR and compatible platforms for motor drive, and sequencing logic.
Ex Machina TF01 — Indoor LiDAR Scanner
Cost-optimised short-range LiDAR unit for indoor spatial mapping, targeting the lower end of a market dominated by expensive commercial alternatives. Designed for use by interior designers, architects, and mechanical engineers working in confined or domestic spaces.
12-metre range covers the majority of indoor applications without the cost overhead of longer-range systems. The two-axis belt-driven scanning mechanism has the main drive pulley molded directly into the chassis body, eliminating a discrete component and reducing both part count and assembly complexity.
Pictured: the Ex Machina TF01X — the experimental development PCB, designed in-house, fabricated by JLCPCB, and assembled in-house. It uses an Arduino Nano for rapid iteration and validation. The commercial version replaces this with a socketed ATMega328PU on a production PCB, reducing unit cost and locking the footprint to the chassis envelope. Both versions integrate dual L293DNE motor drivers and a dedicated LCD display board that carries its own electronics behind the screen, keeping the main PCB clean and the UI self-contained.
Chassis is 3D printed for low unit cost and fast development iteration. Designed and assembled entirely in-house.
Client
Internal project
Year
2018
Modular Race Starter & Timing Display
Large-format modular timing and race control display designed for motorsport and competitive racing events. The system integrates three functional zones in a single unit: a six-digit hh:mm:ss timing display, a two-digit 6-inch countdown panel, and a five-light programmable starting sequence.
The timing digits are built from independently replaceable 4-inch seven-segment modules with a mechanical clip retention system, allowing field replacement without tools or full disassembly. The five starting light pods are user-programmable via an Arduino-based interface, allowing custom sequence timing to match event regulations or race director preference.
All three zones are controlled from a custom master PCB — designed in-house, fabricated by JLCPCB, assembled in-house — managing three independent voltage rails: 5V logic for the MCU, 9V for the 4-inch timing segments, and 12V for the 6-inch countdown digits. Each digit module carries its own 74HC595 shift register, current-limiting resistors, and IC socket on a dedicated board, daisy-chained from the MCU through to the last digit. The architecture is modular and expandable — adding display digits requires only extending the shift register chain.
(Work in progress)
LateBrake — Automobile Brake System
Client
Fusion360 Design Competition
Complete four-wheel hydraulic brake system designed as an entry for a Fusion 360 modelling competition. The brief required fully detailed assemblies with no representative or placeholder geometry — every component complete and every feature named to show design intent. The entry was disqualified on the naming requirement, but the assembly detail drew direct attention from the Fusion 360 development team, who reached out to confirm the renders had been produced entirely within Fusion 360.
The system is built around 2-piece, opposing four-piston floating calipers, cross-drilled and grooved ventilated discs, and a dual-circuit master cylinder with independent reservoirs. Disc geometry is dimensioned to Renault's four-stud bolt pattern and sized to fit the wheel offset of the 1998 Mégane Coupe 2.0L F7R. Caliper, disc, and pad specifications were derived by referencing and reverse engineering published data from Wilwood, Tarox, Brembo, and EBC. The dual master cylinder is fully detailed internally — pushrods, seals, and bleed nipples are all present in the model.
Designed and rendered in five days. The "LateBrake" brand on the caliper is an inside reference — both designer and father are amateur rally drivers.
Model available on the Autodesk Community Gallery:
https://www.autodesk.com/community/gallery/project/38391/automobile-brake-system-education
Year
2016