MECHANICAL ENGINEERING

DESIGN AND SIMULATION PORTFOLIO

Prepared by Engr. John Lloyd A. Vincoy

About me:

Mechanical Engineer with over 5 years of experience in product design and

simulation, focused on enhancing performance, reliability, and efficiency through

cost-effective solutions. Proficient in plastic and sheet metal design, machine

development, 3D modeling (SolidWorks, Fusion 360, and Onshape), and 2D drafting

with GD&T. Experienced in FEA and CFD, with a strong commitment to quality and

continuous improvement.

In my current role at a kitchen robotics company, I am part of the product

development team, responsible for creating and refining 3D components based on

product requirements and delivering manufacturing-ready 2D drawings. I have also

served as an ECO/ECR Coordinator, managing BOMs and leading issue resolution for

manufacturing and field units through timely containment and corrective actions. I

collaborate closely with cross-functional teams and suppliers to ensure technical

alignment and drive design improvements.

Content:

1. Component

a) Plastic Part Design

b) Sheet Metal Design

c) Jig/Fixture Design

2. GD&T Driven 2D Drawings

2. FEA Analysis

3. CFD Analysis

4. Force Analysis (Manual)

Components:

a) Plastic Part Design (Injection Molding)

Product: Top Roast Cover

Software: SolidWorks

Performed Activities:

✓ Completed 3D model and 2D Drawing

✓ Features:

• Surfacing – for smooth debris flow

• Locating feature (pins and holes)

• Uniform thickness on base wall

• Draft angles/holes design

• Structural support Ribs Design

• Extruded features and clearance holes for

screws and inserts

✓ Conducted design reviews

✓ Performed DFM analysis and collaborated with

supplier tooling team

Top Roast Cover – Serves as the full cover of the roast

pan, protecting the heating area from flour residue, dirt,

and liquids. Designed to allow the shaft to pass through

while remaining accessible for the sub-assembly’s

vertical (up-down) movement.

Components:

a) Plastic Part Design – (Injection Molding)

Product: Trigger for Switch (Swiveling with magnet slot)

Software: SolidWorks

Performed Activities:

✓ Completed 3D model and 2D Drawing

✓ Features:

• Locating features (pins and holes)

• Uniform base wall thickness

• Extruded cut to maintain zero-draft shaft hole

• Draft angles and hole design

• Magnet slot with validated pull-out force

(analytical calculation and FEA)

✓ Conducted design reviews

✓ Performed DFM analysis and collaborated with supplier

tooling team

Trigger for Switch (Swiveling with Magnet Slot) – Designed

to activate the micro switch for door detection when

opened. Features a magnet slot to engage with the door

magnet, allowing the trigger to swivel as the door

approaches for closing.

Components:

a) Plastic Part Design – For prototype (3D Print)

Product: Camera Mini ESP32 Enclosure

Software: SolidWorks

Performed Activities:

✓ Completed 3D model and STL file for 3D Printing

✓ Features:

• Uniform thickness on base wall

• Conical feature designed to ensure camera

vision is not compromised

• Extruded features and clearance holes for

screws/inserts and USB-C spacing

Camera Enclosure (Mini ESP32) – Designed to protect

(for 3D printing) the board and camera while securely

mounting the assembly in its intended location.

Components:

a) Plastic Part Design – For prototype (3D Print)

Product: Tachometer Calibrator Enclosure

Software: SolidWorks

Performed Activities:

✓ Completed 3D model and STL file for 3D Printing

✓ Features:

• Uniform base wall thickness

• Extruded features and clearance holes for

screws and inserts

• Cut-outs for 12V pin, reset button, and knobs

Tachometer Calibrator Enclosure – Designed (for 3D

printing) to protect the modified calibrator during daily

use.

Components:

b) Sheet Metal Design

Product: Supporting Bridge

Software: SolidWorks

Performed Activities:

✓ Completed 3D model and 2D Drawing

✓ Features:

• Locating features (pins and holes)

• Gussets for structural support

• Extruded features and clearance holes for

screws and inserts

• Flat pattern analysis to verify bending

clearance before forming

✓ Conducted design reviews

✓ Performed DFM analysis and collaborated with

supplier tooling team

Supporting Bridge – Serves as the connecting support

between the first and second levels of sheet metal.

Components:

b) Sheet Metal Design

Product: Switch Holder

Software: SolidWorks

Performed Activities:

✓ Completed 3D model and 2D Drawing

✓ Features:

• Locating features (pins and holes)

• Gussets for structural support

• Extruded features and clearance holes for

screws and inserts

• Flat pattern analysis to verify bending

clearance before forming

✓ Conducted design reviews

✓ Performed DFM analysis and collaborated with

supplier tooling team

Switch Holder – designed to securely hold a micro

switch, mount in a designated location, and be fastened

with a machined screw.

Components:

b) Sheet Metal Design

Product: Supporting Plate/Holder

Software: SolidWorks

Performed Activities:

✓ Completed 3D model and 2D Drawing

✓ Features:

• Locating features (pins and holes)

• Extruded features and clearance holes for

screws and inserts

• Flat pattern analysis to verify bending

clearance before forming

✓ Conducted design reviews

✓ Performed DFM analysis and collaborated with

supplier tooling team

Supporting Plate/Holder – designed to securely hold the

heating pan sub-assembly, allowing the shaft to pass

through while maintaining accessibility for the sub-

assembly’s vertical movement.

Components:

c) Jigs and Fixtures

Product: Go-No-Go Gap Jig

Software: SolidWorks

Performed Activities:

✓ Completed 3D model and 2D Drawing

✓ Features:

• Locating features (pins and holes)

• Extruded features and clearance holes for

screws and inserts

Go-No-Go Gap Jig – designed for fabrication and use on

the production line to check the end-to-end distance

between two sheet metal parts.

Components:

c) Jigs and Fixtures

Product: Pin Insert Jig

Software: SolidWorks

Performed Activities:

✓ Completed 3D model and 2D Drawing

✓ Features:

• Locating features (pins and holes)

• Extruded features and clearance holes for

screws and inserts

Pin Insert Jig – designed for fabrication and use on the

production line to install metal pins accurately.

Components:

c) Jigs and Fixtures

Product: Belt Installing Fixture

Software: SolidWorks

Performed Activities:

✓ Completed 3D model and 2D Drawing

✓ Features:

• Locating features (pins and holes)

• Extruded features and clearance holes for

screws and inserts

Belt Installing Fixture – designed for fabrication and use on

the production line to install belts and adjust them to the

correct tension and specifications.

GD&T Driven 2D Drawings:

Product: Trigger for Switch

(Swiveling with magnet slot)

Software: SolidWorks

GD&T Driven 2D Drawings:

Product: Supporting

Plate/Holder

Software: SolidWorks

GD&T Driven 2D Drawings:

Product: Switch Holder

Software: SolidWorks

GD&T Driven 2D Drawings:

Product: Bracket - Right

Software: SolidWorks

GD&T Driven 2D Drawings:

Product: Bracket - Left

Software: SolidWorks

FEA ANALYSIS

Activity: Simulate a worst-case scenario with an over-

inserted magnet to evaluate the risk of cracking in the

plastic part.

Software: SolidWorks

Summary: The plastic design (Trigger Switch) will not

experience cracking, even under a worst-case scenario

where an operator accidentally over-inserts the magnet

with a force of approximately 13.4 kgf (shown in

magnet reaction). The part may bend slightly, but it will

not fracture, as the FEA results indicate a maximum

strain of only 3–6 %, well below the 35 % strain at

break of POM M90 Material.

CFD ANALYSIS

Activity: CFD Analysis – Fuse heat simulation during 20 rotis

cooked plus 6 minutes of heating pan warm-up

Software: SolidWorks

Summary: Pans positioned at topmost (home) with 3D-printed

part holding the thermal fuse

During a total heating duration of 1,560 seconds, the following

conditions were observed for the thermal fuse, chassis, and fuse

wire:

• Thermal Fuse: Peak temperature at the fuse body: 70.47 °C

• Chassis:

o Near thermal fuse area: 102 °C

o Behind the loom: 112 °C

• Loom: Peak surface temperature: 75 °C (without heat from

current flow during warm-up)

Recommendations:

Ensure the loom does not contact the chassis at any time;

maintain a minimum air gap of 2 mm.

Maintain a minimum air gap of 5 mm between the thermal fuse

and chassis surface.

Use a plastic material for the thermal fuse holder with low

thermal conductivity, high specific heat, and high deflection

temperature.

Reassess the wire gauge of the thermal fuse loom to ensure it can

handle both heat transfer from nearby components and heating

due to current flow.

Force Analysis

Excel Generated Formula

Manual Solution

Product: Prototype Level – Torque Driver (WIP)

Activity: To perform prototype level force analysis and

validate the estimated torque value and its corresponding

force at the motor side and compare it to the actual load

cell reading. (load cell reading around = 5.2-5.3N).

Summary:

The motor drives the shaft, which compresses the spring

to reach a target “y” deflection. A force value is measured

by the load cell, which serves as the basis for the force

analysis.

To manually verify the load cell reading, the deflection

value is used for a backward analysis. First, the required

axial force to compress the spring is determined, including

the frictional force. This value is then used in the torque

formula for driving a power screw. The calculation also

requires the screw lead angle, mean thread diameter, and

friction angle.

After calculating the torque, the corresponding force is

determined using the given radius from the motor

centerline to the screw hole. The manually calculated

force is 5.3423 N, which closely matches the load cell

reading.

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