Designed a fully detailed hydro-pneumatic shock absorber assembly inspired by US Patent 1,759,674 to commemorate the 100-year anniversary of early shock absorber innovation. The project involved translating historical engineering specifications into a complete digital model using CATIA, incorporating precise GD&T, consideration of tolerance stack-ups, and implementation of functional mechanical locking features. The assembly was developed with a strong focus on DFM/DFA principles to ensure manufacturability and ease of assembly.
Applied structured project management to plan, track, and execute the full design process from concept to finalized CAD assembly. Leveraged advanced complex surface modelling techniques in CATIA to accurately recreate intricate geometries defined in the original patent. Integrated rapid prototyping (3D printing) to produce 30+ physical parts over 48 hours for iterative validation, assessing fit, alignment, and functional performance while refining tolerances and assembly interfaces.
Achieved a fully completed and validated shock absorber design, with all components prepared for final rapid prototyping (3D printing). The iterative design approach improved dimensional accuracy and ensured proper functionality across mating components, effectively resolving tolerance stack-ups and enhancing assembly reliability. The final model demonstrates strong competency in CAD-driven mechanical design, application of DFM/DFA, and the ability to convert legacy engineering documentation into a functional, manufacturable system.
