In a product development project, I designed new sheet metal guards for the belt-pulley system in belt-driven pressure washers to address cracking issues caused by vibration. I 3D printed PLA models to verify fit and tolerances across all units and used these prototypes to finalize drawings. The models were also retained for First Article Inspection of sheet metal samples from the supplier.

At BE’s production facility in Shakopee (MN, USA), the test room exhaust extraction boxes have larger-than-required openings to accommodate pressure washers of varying heights. I was tasked with designing an adjustable cover that can be moved vertically as per the height of the pressure washer to close off one-third of the opening, increasing suction by 33%. I designed a stainless steel (18Ga) sheet metal cover with a tack-welded bracket that grips the complex louver shape of the opening, allowing for vertical adjustment. I also 3D printed a replica to test the design's feasibility.

To improve the process of vacuuming fuel from pressure washer engines after testing, I installed a vacuum hose with a 90-degree bent metal pipe, along with a bend restrictor for better grip and operator convenience. However, the restrictor was too loose and slid along the pipe. To resolve this, I 3D printed a PETG support structure that securely held the restrictor in place. I also designed and printed a TPU holster with a negative impression of the restrictor’s surface, allowing the pipe to be secured by aligning it with the holster.

In a maintenance project, I was tasked with replacing rusted ball bearings in roller ball transfer tables. Instead of purchasing entire new tables, I collaborated with the supply chain team to source alternative roller balls and acquired 4% of the required quantity for testing. However, the samples were 2mm shorter than the existing bearings. To address this, I designed and 3D printed 2mm PETG shims, allowing the samples to be installed alongside the existing bearings for accurate load testing..

At BE's BC facility, some entrance doors had two keypads—an old one and a newly implemented one—which caused confusion among employees. To solve this, I designed and 3D printed blank covers for the old keypads, eliminating the confusion and enhancing the aesthetic of the entrance.