https://www.davidbunn.me/about daily 0.75 2024-11-29 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1583383237182-1PBNM0F6UDGF0RN12660/Headshot2020.jpg About - About Me BSE in Mechanical Engineering and Applied Mechanics, MSE concentrating in Design and Manufacturing at the University of Pennsylvania. Former Powertrain Lead on Penn Electric Racing. Currently Starship Electronics Production Engineer at SpaceX. https://www.davidbunn.me/art daily 0.75 2020-08-05 https://www.davidbunn.me/art/cellink-sponsor-photos monthly 0.5 2019-12-14 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1576286084105-JRA10FTJ0L5Z1XTR5FAL/1X6A2265-Edit-Edit.jpg Art - CelLink Sponsor Photos https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1576285782625-XFSA766YETWW8DHTV47C/1X6A2245-Edit.jpg Art - CelLink Sponsor Photos https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1576285781246-AANRMDEEZLQGEX7HO98U/1X6A2188-Edit.jpg Art - CelLink Sponsor Photos https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1576289722994-61HXGUX2L5S9YNHC7YMW/1X6A2249-Edit-Edit.jpg Art - CelLink Sponsor Photos https://www.davidbunn.me/art/unveiling monthly 0.5 2019-12-14 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1576284010911-OA8RNPTTWS3TJ7UHUS2C/4I0A9897.jpg Art - Unveiling Video https://www.davidbunn.me/art/macro monthly 0.5 2019-12-15 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1576287636776-XSMHRL4E16WP39XSL35X/Bunn_David_FinalProject_1.jpg Art - 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It dates back to the 90’s and uses technology from even earlier. Historically the Penn Electric Racing team has been the only on-campus organization with the need for the machine, and has had sole responsibility for its upkeep without support from shop staff. Unfortunately, in the past year or two it encountered a seemingly fatal error and the team was unable to continue working on it. The select few who knew how to operate it had graduated without properly teaching a new member or creating thorough documentation. I embarked on the journey of getting it fully operational, starting essentially from scratch facing an error code I knew nothing about on a machine I didn’t know how to operate. With my background knowledge using other CNC mills and the help of one recent graduate I was still in contact with, I went through the debugging process. I read countless online forums and pages from the manuals and eventually fixed each successive error, learning how to operate the machine along the way. In the end the machine was back to its former glory and I was able to produce a few parts, write a new condensed operation guide for future users, and even test the 4th axis before the COVID-19 quarantine shut everything down. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1591073186682-P492WJT5YE91MNW8QY92/IMG_3790.jpg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1590991708862-JUD3PBTEDGBWX81TDN6B/IMG_3840.jpeg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1590991893779-LHWAJ1BG0Y0DHL1BYF0A/IMG_3929.jpg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1590989456668-H13VOVISUXRGXULB1NA0/IMG_3159.jpeg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1590989458890-TJKU6IU0RTEP1U5A2BXR/IMG_3217.jpeg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1590989459150-WEJC0LNHZSBLPF9WLM2A/IMG_3191.jpeg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1591074808692-HRQQ1NADAFHDIUDSYHDP/IMG_3693.jpg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1590989857346-9DOYDB1KCZCAG84GQP71/IMG_3730.jpeg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1590989858464-N31EQIUJQGP0I2ZW63LN/IMG_3736.jpeg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1590990581387-8R1AET7OKE3KLVQE9SUP/IMG_3751.jpeg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1590990583082-ID9Y2JFYHL3QW8Z0WFL8/IMG_3755.jpeg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1590990584151-EA27GVZ6VPJJAIYH97GK/IMG_3757.jpeg Work - CNC Restoration https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1590990585535-E2Y4XXNRCCYKJL19QXZA/IMG_3759.jpeg Work - CNC Restoration https://www.davidbunn.me/work/dissect monthly 0.5 2019-12-14 https://www.davidbunn.me/work/rotor monthly 0.5 2020-02-19 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575951757758-D41U14PDDK95PRDFNA5N/FullHelicopterRender1.JPG Work - Rotor https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575951936131-PQ4KVTUVBK0DMTW0H6NP/RotorRender1.21.png Work - Rotor https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575951927955-8FG171OFQTD8QQDKJGYR/20140301_Trade-151_0124-copy.jpg Work - Rotor https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1601048548856-K25K0OFSU59I9OIT8G3Y/501Final.jpg Work - Rotor With copious issues with parts purchasing, composite molds failing, and lack of time to test and iterate, the final product didn’t turn out how we wanted it to. Nonetheless, it was able to display the core function of the rotor mechanism. https://www.davidbunn.me/work/engine monthly 0.5 2019-12-15 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573609344794-CP5AFIK8Z6UKAKLH9N68/MEAM201_18C_LightBox+%2849%29+%281%29.jpg Work - Stirling Engine https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573609518628-OXQCNUBI2YKSLJCMQSRW/EngineISO.JPG Work - Stirling Engine - Designed in SolidWorks I designed this Stirling engine inspired by a car wheel. The brass hub is expanded to represent the spokes of the wheel and bolted to the flywheel which emulates the tire. All parts were modeled in SolidWorks, with some some non-machined parts given, and mated into an assembly with working motion mates. For each machined part, I made engineering drawings with GD&T, and also calculated a full-engine tolerance stack-up to determine critical tolerances in order for the displacer to interface correctly with the air chamber. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573611279814-CCDNMBDF39XU8S11YTQY/Bunn_FlyWheel_Hub_OutputShaft-page-001.jpg Work - Stirling Engine - An Introduction to Machining Throughout the semester I machined over 15 individual parts out of aluminum, brass, and steel on 3-axis manual and converted mills and lathes, including 2-D CNC toolpaths. Several parts required fixture setups which I also designed and machined. After assembly, the engine flywheel spun at over 1350 RPM with a heat source applied to the air chamber. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573612853359-RRSSCCV3QLKB9Q8MHBAE/MEAM201_18C_LightBox+%2856%29.jpg Work - Stirling Engine https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573613199205-GP3H1QM8316Z5S7T7SA2/MEAM201_18C_LightBox+%2862%29.jpg Work - Stirling Engine https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573614320379-Z1JTKUORX3MKLBJ2DLRV/IMG-0684.jpg Work - Stirling Engine https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573614319842-4IZ5742J06F5T5Q3BVAY/IMG-0699.jpg Work - Stirling Engine https://www.davidbunn.me/work/injection-mold monthly 0.5 2020-08-24 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573684461474-WAHTFQA0IIF49VJ39JMU/IMG_1176+2.jpg Work - Injection Mold https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573685987155-EW6PA2XUNQ9KHJ8155JA/IMG_1169.jpg Work - Injection Mold - Process Optimization We molded a variety of parts, learning the sensitive settings of the Morgan Press injection molding machine to reduce sink, flash, and short shots. We experimented with different mixtures of dyed HDPE and figured out the recipe for a marbled look. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573684654705-KJ8K0MFNCZMOCE4DK853/IMG_1156+2.jpg Work - Injection Mold - 2-Part Injection Mold In a team of two, I worked with SolidWorks Surface Modeling and Mold Tools to design a toy airplane inspired by the Lockheed Electra, considering critical molding aspects like the sprue, draft, parting line, and sink. While designing the part, we optimized these parameters by running flow simulations to predict and reduce undesired results. I machined the core component of the mold using a 3-axis CNC mill, which features internal ribs in the fuselage and engines to reduce part thickness (and sink), as well as the sprue hole and locating pin holes. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573688105005-3QR5RGZAKGHQUNMJVUQK/Screen+Shot+2019-11-13+at+6.24.06+PM.png Work - Injection Mold https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573700656058-WMSGCQPYHTLWQSD5G822/Screen+Shot+2019-11-13+at+6.38.48+PM.png Work - Injection Mold https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573703232604-JCHIRP5PACAJO2NF030K/IMG-1113.jpg Work - Injection Mold https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573703243694-9ZZ1I4ZLPONC6GBM8ETR/IMG-1114.jpg Work - Injection Mold https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573687947289-QQJCXTWR22H14XWZKCFO/IMG_1161.jpg Work - Injection Mold https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573699824587-XY9TEWDKON7K4BT6A1DE/Flash.jpg Work - Injection Mold https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573700081020-03GHEBAQJIHORL5DHOGK/Process.jpg Work - Injection Mold https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573688684632-S3G04TBHTERVE5JEILPR/Screen%2BShot%2B2019-11-13%2Bat%2B6.43.22%2BPM.jpg Work - Injection Mold https://www.davidbunn.me/work/sabre monthly 0.5 2020-08-24 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573783614824-UN6PXWX0MPN354IL2QWH/IMG-1080.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573630155297-K623NCZ6YV9ZW592R5YR/Render4.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573630106851-AZLOO80KOV78848GJHZW/CandyMachining.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573629819826-A3B51Z6WFTEWVUZW53GB/CandyCAM.JPG Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573711919661-65FKRAQMO8NAD0HRD5K2/IMG-0998.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573711927010-L8ZBJZ7890NAJMHKYOY3/IMG-1012.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573711933824-9R4XXFVZJKV8UKOA0ICV/IMG-1030.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573711953801-O5J3QEHHR9IOHQ38FPEB/IMG-1051.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573631525397-NCNXTY1QK75L94NI1L2F/IMG-1038.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573711978962-ILRWCR2E3YHNP416IGVI/IMG-1053.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573631485888-U0LPZSELDT5W6NJOAP6O/IMG-1057.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573631559565-2I6VL52Y3HOAEAPBH4Y8/IMG-1065.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573632189459-LV7S2FYOMA5M2E24YM8U/IMG-1067.jpg Work - F-86 Sabre https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573711588278-ZE22HAZFVAMKF94IKWVK/IMG-1085.jpg Work - F-86 Sabre https://www.davidbunn.me/work/chess monthly 0.5 2020-08-24 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573633829482-9J2L9ZMUAOLCYG9C6NVA/1X6A9199-Edit%252B%2525281%252529.jpg Work - Chess https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573666393849-32BC9RFDJSZVFONZ41ID/1X6A9268.jpg Work - Chess - Modern Design & Manufacturing I worked with a team of 5 to design and manufacture a chess set using a CNC lathe. The upper halves are made from polycarbonate, sanded to a frosted glass look. The bottoms differentiate the teams, made of polished copper and aluminum to keep the center of mass low and prevent tipping. Post-operations were done on a mill to create piece-specific features. With dozens of repeated parts, we worked to streamline the manufacturing process while ensuring each piece had a uniform and consistent finish. The bottoms are identical for all pieces, and the copper squares were machined using a fixture that reduced setup time while still achieving tight tolerances for the inlay fit. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573667188672-4QRKG5BP9FGGPZQOX3NB/1X6A9235-Edit+%281%29.jpg Work - Chess - Design & Aesthetic The board is made from aluminum brackets with copper inlay, polished to a mirror finish. The rows are held by a steel spine, staggered to give the appearance that the board is floating. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573667627733-VESNZ75E73YCI2K90YR6/1X6A9262-Edit.jpg Work - Chess https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573667521021-PCQFPP7BRQO9TQQT43L1/1X6A9219-Edit.jpg Work - Chess https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573667622315-KKLXC3R3W69IE4Y4PZ2Z/1X6A9233.jpg Work - Chess https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573667513217-X0OBKS9PAEHEWHE0P6PU/1X6A9240.jpg Work - Chess https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573667657156-L09P9X02SXI8178YKMEV/1X6A9271.jpg Work - Chess https://www.davidbunn.me/work/swan-necks monthly 0.5 2019-12-14 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1576039290063-I2SW7M4ZTRHU7IIJX83M/Render_CarPaint.JPG Work - Swan Necks https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573790846964-H7DHSII92CJ1UTY4IVZ8/Screen+Shot+2019-11-14+at+10.40.12+PM.png Work - Swan Necks - Finite Element Analysis By making a 2D simplification of the linkage geometry, I was able to model and simulate the loading conditions with SolidWorks FEA. The loads were applied at the pin joints, broken into lift and drag components, using Cl and Cd results from STAR CCM+ CFD simulations on the wing. Since downforce is twice the magnitude of drag, the Swan Neck is primarily loaded in 3-point bending. The middle joint is being pulled down since the wing’s aerodynamic center lies along the 1/4 chord of the airfoil, closest to the middle joint. The exact loading is not as simple because of the other pin joints between the wing/endplate (modeled as a triangle), the vertical supports (left rod), and the fixed chassis (right rod). These members were assumed rigid to compute stresses in the Swan Neck. After 6 design iterations, running FEA on each to optimize parameters, the final design had a minimum safety factor of 2.5 for the von Mises yield criterion, weighing only 0.472 lbs each. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573790813171-KMXJM4SX9VAW1M5JPAAD/IMG_1814.jpg Work - Swan Necks - Rear Wing Structure Swan Necks are the backbone of the rear wing mounting system. They are designed to carry the aerodynamic loads of the rear wing, which produces upwards of 360 lbs of downforce at a top speed of 90 mph. I worked to minimize weight, improving by over 50% from the previous design. The other elements of the mount are carbon tubes with spherical rod ends: a cross brace seen on top and vertical supports under the wing. This complicated 3D linkage presents challenges in calculating the expected loads and linkage behavior. The Swan Necks have three pin joints, with a truss structure optimized to carry the moment loads produced by the linkage. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573794468554-WSRKD09B4RFR9A94306X/Screen+Shot+2019-11-15+at+12.07.05+AM.png Work - Swan Necks - Buckling Analysis I investigated stress normal to the cross section of the members to see that the entire structure was bending rather than just individual members, indicating a more stiff and weight-efficient structure. This is seen from the blue compressive stress along the top edge and yellow tensile stress along the bottom edge. I used this result at the members most likely to experience buckling, the longest members in compression, and calculated the thickness required to achieve a minimum safety factor of 2.5 for the buckling failure mode. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1576037540172-A5C9937DE8D09CAWTQQL/1X6A2134.jpg Work - Swan Necks https://www.davidbunn.me/work/portescap monthly 0.5 2019-12-14 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573966298572-0KQ6Y2E69XBTDR38HRME/DrillAssemblyDrawing.JPG Work - Portescap R&D https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573854471773-NT84NZZQXODPMXSR6Y1I/IMG_2261.jpg Work - Portescap R&D https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573853567673-WNQH79V1VCSICRWUPA13/IMG_2216.jpg Work - Portescap R&D https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573853514704-9KELLRMO550GW7SDW1KF/IMG_2215.jpg Work - Portescap R&D https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1573853042912-IFXX8CITZI1XYQDCHS75/IMG_2217.jpg Work - Portescap R&D https://www.davidbunn.me/work/bungee monthly 0.5 2020-08-24 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575663766950-1MFCQTG9YD4RWHW3D0ZB/BungeeCover.jpg Work - Bungee https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575663946925-WV939JNQIU0784DDOOE6/MTS_Testing.jpg Work - Bungee - MTS Data Collection A variety of rubber band configurations were tested on an MTS machine, measuring force vs. displacement rather than the standard stress vs. strain data since the cross sectional area changes as the rubber is stretched. This data was compiled along with the full class dataset to have a 95% confidence interval accounting for variations in rubber bands. A cubic function was fit to the data due to the hyper elastic properties of rubber. We used this in our MatLab model, using energy calculations to determine the dynamic properties of different bungee configurations. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575665416401-NU4MIIN102J0JSKAYW6R/BungeeFinalConfiguration.jpg Work - Bungee - MatLab Model Our model consists of an input and graphing script and 3 functions. The given information for this project was a range of input variables: object mass between 0.2-2 kg, a G-limit on acceleration between 4-7 G’s, and a range of drop heights between 6-100 ft. Given a set of inputs the first function iterates through a range of configuration parameters for the length of string, number of bands in series, and number of bands in parallel. This function checks whether each configuration doesn’t hit the ground or exceed the G-limit. The other two functions calculate the transfer from potential to spring energy, using the spring force function fit from our data, to determine the maximum extension of the bands. I made a MatLab script to plot the solutions on a 3D figure so we could visualize the range of possible configurations and the free fall “score” associated with each. This proved extremely useful for our model debugging and validation testing to build an intuition for which solutions made sense and also see the sensitivities to different parameters. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575667153978-80CTNUJ9DYLX4XXDP1AF/BungeeDropTest2Graphs-Edit.jpg Work - Bungee - Validating the Model We used our MatLab model to calculate configurations for smaller test drops and assembled a bungee with a weight and accelerometer attached to test the predicted performance. The accelerometer data helped us eliminate errors and verify that the model was working correctly at the small scale, giving us confidence that it would work at the large scale. When all the accelerometers were inevitable broken by the class testing unreliable bungee’s, I repurposed a MatLab script I wrote for a previous class that was originally used to calculate G’s using video point tracking for a car crash test. We tested the final versions of our model by taking slow motion video at 240 frames per second, and using this script to track the motion, resulting in the graph on the left. The results were actually quite accurate, giving a maximum acceleration of ~6 G’s for a 7 G limit. We also confirmed the accuracy of this method by using it on the final drop video and comparing with the onboard accelerometer. https://www.davidbunn.me/work/vawt monthly 0.5 2020-08-17 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575940420559-BBCPG9GRQYSDT7F8H557/IMG_2940.jpg Work - VAWT https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1597690094743-BN3QLN6PVZ9GF90QL9V5/VAWT_Cp_vs_TSR.JPG Work - VAWT https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1597689908508-YBIW42SC9ORS2EQGOLB3/VAWT_raw_data.JPG Work - VAWT https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1597690906492-U6D0CLVNBCMBNUMWHQOZ/VAWT_final_data.JPG Work - VAWT Data from actual run. Readings before ~38s are test spins by hand. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575936312133-YY02AEFP1B30TERCL0JO/Screen+Shot+2019-12-09+at+6.52.20+PM.png Work - VAWT https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575937574144-IHZMEYVU60O0NBI8WKB2/Screen+Shot+2019-12-09+at+7.23.57+PM.png Work - VAWT https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575938568838-D76LM379VDTKZ4MER8V2/IMG_2999.jpg Work - VAWT https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1575936322544-Y5SQXEX6QUVQBGILY1X4/Screen+Shot+2019-12-09+at+6.52.40+PM.png Work - VAWT https://www.davidbunn.me/work/pcm-box monthly 0.5 2020-08-24 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1579422071577-WQQKP13I7FW7OXRWNTHO/IMG-1794.PNG Work - PCM Box https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1579424453005-CE0PIIY0DMFQU0M2U0T6/IMG-1856.jpg Work - PCM Box - Compact Design Three main boards, the Powertrain Control Module (PCM), Standalone Data Logger (SDL), and Power Distribution Unit (PDU), are packaged as efficiently as possible, sliding on rails and connecting to the PCM connector board with gold fingers. The design incorporates poka-yoke style keyed slots such that boards can’t be inserted upside down or in the wrong slot. The middle divider also doubles as a support for the widest board, the PDU, in order to reduce board flex and vibrations while driving due to the 8 heavy 18650 batteries. The enclosure is 3D printed in ASA plastic to remain as light weight as possible, and uses heat set threaded inserts for secure attachment of components. https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1579424488882-S986QWSJTEDUWWA9NCGH/IMG-1858.jpg Work - PCM Box - Optimized for Accessibility The PCM box features a latched access panel on the outward facing side for easy access to the boards with fast attachment and detachment, necessary during frequent debugging while testing the car. The inward facing panel secures the connector board, where 5 autosport connectors link the PCBs to the car’s wiring harness. The 3D printed parts are coated with a sealant for waterproofing, and each panel is designed with an overhung edge and gasket foam to seal the interface. The front panel can either be sealed by the sprung latches, applying a clamping force, or with 6 screws for a more secure seal for added protection during competition events. The box is attached to the chassis with two tabs and positioned in an easily accessible spot for both the outward panel, which is used to access the boards, as well as the inward panel where the wiring harness connectors must be attached, all while fitting between the suspension and seat firewall. https://www.davidbunn.me/work/rev6-powertrain monthly 0.5 2020-08-24 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1592118292978-QLZAGKR97D2IBM2GEW4Q/Unsprung+Exploded+Final+Render.png Work - REV6 Powertrain https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1600997729291-21YEAT1FEQWXZM3PV24Y/car_minus_aero.jpg Work - REV6 Powertrain https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1598128746732-S31V9L9UGKKXJM7LLVK2/Upright+Bearings.jpg Work - REV6 Powertrain https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1601002243151-R0NMYA2KAG0NH4A2P7JJ/UprightFEA-Stress.JPG Work - REV6 Powertrain https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1601047533707-FYX5RLABWI9OB2GIP0F4/UprightFEA-Loads.JPG Work - REV6 Powertrain https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1601001359164-LNJTYECXNL5HQ6G5EQQ3/UprightFEA-Mesh.JPG Work - REV6 Powertrain https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1592711565768-I09LL2KUJ98TMT8Y17OS/NEW+REV6+Top+Assy+Rendering+2.jpg Work - REV6 Powertrain REV6 is Penn Electric Racing’s 7th car, which competed in the 2020 Formula SAE Virtual Collegiate Design Series. It’s predecessor REV5, which shares much of the same powertrain design, competed in the 2019 Formula SAE Lincoln International Competition and placed 3rd overall among 30 electric teams. https://www.davidbunn.me/work/hoverbarrow monthly 0.5 2020-05-31 https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1589330592110-91YJIA0KPA6ZTMW4RD8W/Hoverbarrow_Full.50.png Work - Hoverbarrow https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1589333753941-53EBZLENSFYRCAZ8AYJ7/Frame2.jpg Work - Hoverbarrow https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1589333571175-4W2PMRMAEGRVBBSDS9C9/ShellBottom.69.png Work - Hoverbarrow https://images.squarespace-cdn.com/content/v1/5dcb33740bdbc90996fd4f3b/1589333538821-N4XTWROH1YN4LA7VS5G5/Shell.68.png Work - Hoverbarrow The Hoverboard Shell is Injection Molded from ABS plastic and features uniform wall thickness with structural ribs and bosses for thread-forming screws. 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