Case Studies
LIQUID CRYSTAL TUBE HEATER
Requirement:
To hold a vial of Nematic Liquid Crystal solution in a powerful magnetic field at a closely controlled and elevated temperature whilst 'observing' the structural change with shallow angle XRD (X-Ray diffractometry)
Solution:
An electrically isolated cradle to hold a graphite rod bored 1mm diameter to hold the vial. Using a PID controller the rod acts as a resistive heater.
The heater rod is held between two focused neodymium magnets and the gap width can be adjusted.
Shallow angle XRD captures the structural changes for the nematic liquid crystal as it passes through the transition temperature.
HEATED BIO-BOARD PRESS
Requirement:
To provide a heated press to apply uniform temperature and gap thickness. Maximum temperature and pressure 240 deg C and 2 MPa.
Solution:
Design and manufacture a freestanding press with fixed top caul plate and sliding lower caul plate. Incorporating a commercially available 20 Tonne double-acting ram with industry-standard geared hydraulic pump and single phase electric drive. Stressed parts were designed to withstand the forces applied. The caul plates are heated with embedded ring style resistive heaters and PID controlled.
Press rates can be manually adjusted via a proportional control lever and press force and over pressure controls are in place.
Image show the development stage, prior to commissioning and handover operator safety interlocked guards were incorporated.
Further development:
Subsequent testing was required; from the requirements outlined in the relevant BSI documentation we designed and manufactured jigs for 4-point bend testing and internal bond testing (shown below) to be used with INSTRON universal tester.
INCONEL HEATED & STIRRED REACTOR
Requirement:
The researcher wanted to stir a mixture of sodium hydroxide solution with potash at elevated temperatures.
Solution:
The caustic solution posed an interesting challenge due to its aggressive nature; stainless steel was not suitable and a grade of INCONEL was chosen. For the containment of the solution, this was a closed unit with a magnetic drive used to provide rotation. This project required careful consideration of materials, especially for the bearings to mount the rotating shaft.
The design allowed for initial low-volume processing then with a simple changeover, a large-volume body and extended stirrer could be used.
UV SAMPLE MODIFICATION
Requirement:
To irradiate a sample with a specific wavelength, in this case the UV spectrum.
Solution:
Working around standard sample holders for the particular applications, mounts or plugs were designed to hold or fix in place. Given the mass-produced nature of some of these, design tolerances had to be considered to ensure compatibility across batches.
Due to the power ratings and longevity of some of the sample runs air heat sinks were designed and manufactured.
HYDROTHERMAL REACTOR
Requirement:
A self-contained reaction system to be heated with no external inputs. Due to the chemistry, an inert liner is required with safety over pressure considerations.
Solution:
This is a variation of a known design. It is a PTFE-lined vessel and sealing lid, supported by a stainless steel housing. There is a spring to ensure the pressure is maintained during the reaction.
NOTE: This system was operated in a fume hood for safety.
UHV COLD CELL
Requirement:
To provide a vacuum chamber with 'windows' for a line of sight through for laser excitation of atmospheric gases whilst cooled.
Solution:
I designed a jacketed UHV chamber with Indium sealed windows suitable for the wavelength/chemistry. Mounted to sit inboard of a secondary medium vacuum system with glycol cooling via heat exchanger system.
MICROWAVE PROCESSING - RECIRCULATION PILOT PLANT
Requirement:
Working with other contract engineers my requirement was to design and manufacture a skid for the processing equipment. This included pipework layout, manufacture and assembly to allow installation into a confined space and allow disassembly for cleaning and maintenance.
Solution:
Design of a recirculating system to recirculate orange peel pulp through a microwave generator to heat continuous flow. This transports the media through the waveguide and then into a drop vessel and the process continues until the media has reached and maintained the desired temperature for the desired length of time. The temperature dependant factions are then extracted to another vessel.
BESPOKE GLOVE BOX
Requirement:
The customer had a need for a bespoke glovebox with oversized access requirements and tailored I/O's, there was not a commercial solution available to provide the size at budget or lead time that was acceptable.
Solution:
Following consultations, a full requirement specification was developed to account for future work envisaged. Large access port and small/large anti-chambers were designed to allow passage of equipment and experimental equipment to be transferred into and out of the glove box. Due to the large size of the anti-chamber calculations were performed to ensure there was no significant deformation/collapse during evacuation cycles. These were validated with FEA studies.
Isolated feed-throughs were installed with redundancy to allow for further development.
Specialist 3rd party manufacturers were identified for the manufacture of the main enclosure and the machined components were optimised (DFM) for in-house manufacture.
REFLUX RIG - PARALLEL REACTOR
Requirement:
Perform parallel reflux reactions.
Solution:
Development of a known system to design a heated base unit connected to a water/glycol cooled upper with a distribution manifold to feed each cell.
ELECTROCHEMICAL CELL
Requirement:
To deliver a sealed with gas flow through the cell with a conductive link between the graphite liner and housing.
Solution:
Design of an aluminium housing with a low impurity graphite machined liner with a defined active surface.
An array of inputs for gases in/out and electrodes.
The unit is sealed with an elastomer seal to prevent loss or ingress.
https://chemistry-europe.onlinelibrary.wiley.com/doi/full/10.1002/cssc.201702087
CUSTOM MICROWAVE WAVE-GUIDE
Requirement:
Change in the application requires a larger through bore.
Solution:
Redesign and manufacture of waveguide with increased through bore.
PULSE TUBE ADAPTER
Requirement:
Part of a Parahydrogen system also designed and built requires a vacuum adapter flange to connect to a commercial pulse tube cryo-cooler.
Solution:
Design and manufacture of a stainless steel three-part vacuum welded flange. Vacuum and telemetry port incorporated.
Material, weld integrity and design, surface finish and tolerance were key to ensure safe operation.
GANTRY FOR NMR
Requirement:
To provide a safe working platform to load/unload samples and to perform liquid helium fills for the NMR machine.
Solution:
Design of non-magnetic welded aluminium steps and platform integrated with safety rails.
Access was an issue both for the welding booth available and installation into the laboratory.
Access for the large helium dewars and relatively short transfer lines restricted platform size and step location.
CUSTOM SLEDS
Requirement:
Field replaceable sleds to carry electronics for MEG (Magnetoencephalography).
Delicate/low-noise electronics require thermal management.
Solution:
Identify a suitable 3rd party standard server rack, where possible utilised off the shelf components.
Electronics sleds were custom designed with forced air cooling into the cabinet and manifolded across the sleds to give priority cooling to specific areas.
The backplane location was designed in to allow secure alignment during assembly and inevitable field testing. There is around 2000 signal wires to connectors entering the cabinet.
SHELL MILL FOR GCMS
Requirement:
To capture and analyse the gas chemistry given off immediately after breaking up marine shells and archaeological artefacts. To then feed a carrier gas with any emissions through a GCMS.
This is a sealed grinder/mill for hand operation with feedthrough for carrier gas to GCMS.
Solution:
Design and manufactured from stainless steel and brass with a polycarbonate shell to observe the process. There is dynamic seals to allow the mill to be rotated with no leakage and the grinding head is spring-loaded to provide constant force.
H2 FILL MANIFOLD
Requirement:
To provide multiple gas feed sources to fill NMR sample tubes.
Solution:
A simple stainless steel manifold with industry-standard pressure fittings.
LOW PRESSURE REACTION VESSEL
Requirement:
Low-pressure heated reactor to investigate emissions from mineral automotive lubricants. Safety relief must be incorporated.
Solution:
Design of a stainless vessel with multiple welded compression fittings in the lid. Bespoke low-pressure burst disc designed and incorporated.
DESIGN FOR ASSEMBLY
Requirement:
To produce 'dog-bone' samples of adhesive to carry out cohesion test.
Solution:
Following BSI standards for size and form, an aluminium positive was manufactured which in turn was used to make a flexible silicone mould.
MULTI-POINT REACTOR
Requirement:
To carry out parallel reactions with different compounds under the same operating conditions. Must withstand an array of aggressive solutions.
Operate at high pressures and elevated temperatures.
Solution:
Designed and manufactured from INCONEL for severe service and 316 for standard use.
Six independent pockets are machined into a common body with O-ring seals to suit the chemistry used. A secure locking ring closes the assembly with a common gas feed to each pocket which is independently valved with a 3-way valve.
PT2 THERMAL STAGE
Requirement:
Provide a cooling stage for 360 superconducting devices within a predetermined footprint.
Due to the nature of the system, this was in a vacuum chamber operating at 20 K.
Solution:
Looking in conjunction with all the other mating parts, some of which were not fully defined, the design had to hold 12 PCB modules fastened to a gold plated oxygen free copper plate. The plate had to incorporate many fastening points, feedthru's and clearance pockets.
HIGH TEMPERATURE REACTION VESSEL
Requirement:
A high-pressure, high-temperature reactor with minimal volatiles to leach out.
Solution:
One criteria was to not use 316 stainless steel due to the molybdenum content having an adverse effect on the chemistry of the experiment. Also due to the elevated temperature/pressure 304H was chosen due to higher C content.
A soft copper seat as pressed in and high tensile clamp bolts were chosen with a limited lifespan/replacement cycle.
TEMP CONTROLLED CELL
Requirement:
Provide a temperature-controlled platform to carry out electrical conductivity measurements of various coatings.
Solution:
A large copper mass with a cartridge heater and feedback to the PID controller.
A pressure plate to insulate from heat loss and carry electrodes embedded.
GLASS REACTION VESSELS
Requirement:
In varying forms and requirements to couple up with custom or off the shelf standard glassware.
Typically containing solutions at elevated temperatures or irradiated.
Solution:
Working around the glassware and requirements, design and manufacture sealing/feedthrough adapters allowing for variance. Incorporating safety guards where required and mounting solutions.
HUD MOUNT
Gollem HUD holder AP systems
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Solid 3D resin print for AP rebreather to hold HUD in place for viewing whilst using GOLLEM Shrimp BOV.
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Can be fitted without removing or squashing any hoses.
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Two-piece construction hinged with soft mating face
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Can be fitted either side.
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Contact me if you have other units you would like to fit to, design sizes can be modified.
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All metal parts A4 stainless steel so no corrosion.
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Tested on my unit to 40+ m, no voids for moisture/air uptake.
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Colour may vary please advise if you would like a specific colour (surcharge may be added)
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£45 Each delivered UK mainland.
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These are printed to order, I will aim to ship 2 - 3 days from point of order, however please allow up to 2 weeks (just in case I am away diving).
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If urgent please advise at point of order.
Disclaimer.
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These are plastic parts and like the rest of your gear, if you drop something heavy on it will break!!
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In this event, individual replacement parts can be shipped.
CONTACT US FOR ENGINEERING DESIGN AND PROTOTYPING SERVICES
If you have any questions or concerns, please contact us to learn more.
Unit 3 Birks Old Shop, Buttercrambe, YORK YO41 1AR
07488 387037