Projects while at 219 Design
San Francisco, 2018 - 2024
219 Design is a top engineering consultancy in the San Francisco Bay Area
Most of our clients at 219 Design kept their projects confidential. However, here are a few products that we are allowed to talk about.
For each of these products, I was involved from the starting blank-slate brainstorming, through the rapid prototyping and detailed engineering, and up till the launch into market introduction.
Purcell S1 Bulk Food Dispenser
219 Design acted as Purcell’s engineering department, helping develop and construct pilot units for real-world testing in a set of select grocery stores.
Abe’s efforts included
Lead the design process for the “Agitation system”
Brainstorming: ideated food agitation methods with the team
Prototyping: made rapid versions of 4 food agitation methods, such as sawtooth board made from cardboard and wood.
R&D: developed experiments to quantify food agitation methods
Individual parts: designed a 3D printed agitation interface
Ramp to production: sourced motor vendors
Worked with team in the above design process for 10 systems: weight architecture, valve design, cartridge release, etc…
The Purcell S1 Dispenser won Platinum in the Spark Design Awards for sustainability.
Carbon Smart Part Washer
The Carbon Smart Part washer cleans excess resin from 3D printed parts. 219’s experience designing ruggedized mechanisms enabled us to redesign the rotating clamp mechanism to increase the lifespan of the Smart Part Washer.
Abe’s efforts included
Troubleshot and re-designed of the compression architecture with the 219 Design team
Performed static + dynamic load calculation and FEA simulation
Did a deep dive into angular contact bearings
Calculated bearing fatigue and bearing lifetime
Designed the belt tensioning system
Generated a BOM and sourced suppliers
Wrote assembly instructions and performed on-site assembly
Scooter Smart Lock
219 Design raced to get thousands of custom head tubes with integrated smart locks designed, developed, iterated, & manufactured in months. We earned a key operating permit with San Francisco, while the client’s competitors were banned.
Abe’s efforts included
Made an arduino-controlled linear actuator mechanism for repetitive life-testing the lock
Ran experiments with testing lab for vibration and environmental durability
Traveled to Shenzhen, China for on-site ramp-up of first 1k units
Brainstormed and prototyped next generation lock architecture with the internal team
SilvaClean Laundry System
219 Design helped Applied Silver reposition their product into major league sports through a successful debut at the 2019 NFL Combine.
Before
After
Abe’s efforts included
Design for manufacturing (DFM) - shrunk the unit volume and refined assembly access
Designed sheet metal structure supporting an aesthetic shell
Sourced and worked with part vendors
Ramped up onsite production to 20+ units
Created Bill of Materials and assembly instructions
Puck Test System
219 built a rugged fixture to test the functionality of sensorized pucks for the National Hockey League.
Abe’s efforts included
Brainstormed UX architectures
Rapidly prototyped puck lifting mechanisms
Designed the puck interface
Simplified user operation and reduced cycle time
Concentrated complexity, including a mechanical flexure, into 1 part
Scalable durability - integrated the fixture into a standard Pelican case
Developed the manufacturing & assembly procedures
Led 2-person team to assemble & deliver 30+ units on time and under budget