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Crowd Sourced Engineering

Over the past 4 or 5 years I have watched the growth of crowd sourced design.  I have seen protein folding projects claim success by harnessing the crowd.  I have also seen SETI grow their search for life from harnessing thousands of computers to now also harnessing their owners. I have not personally taken part in any projects, so I went looking on the web to see any engineering design projects had used crowd sourcing and how the community perceives their success. I was able to find articles on completed software and bio engineering projects but non on any completed design projects.  However I also found a lot of engineering crowd source projects still running; NASA crowd source project, DARPA crowd source project, Open Source Rocket and a few others.  All of these projects made me a little excited and a little scared.

As a designer in the aerospace industry I am all too aware of the amount of control, checks and rechecks that go into the design and fabrication of aerospace products. The design of simple angles may be controlled by over 20 spec documents and need to be reviewed by 15 subject matter experts before it can even go out for bid to a supplier.  Once the supplier fabricates the part easily over 30 sped documents were referenced and several levels of quality check will have been performed. Lastly, the parts are continually inspected as they are received and added to the assembly or product. And even with all of those reviews 25% of a program’s budget usually goes to rework.  So this experience begs me to ask a few questions:

  • How much accountability can be built into crowd sourced engineering? 
  • How much efficiency is lost in crowd sourcing your engineering?
  • What specs, processes and controls will need to be created to make these projects viable?
  • What data formats and change management systems are used to ensure that downstream stake holders of the engineering output can plan their tasks?
  • How is functional commonality achieved? ie. how do you know all of the parts are being stress analyzed the same way?

 

I see some solutions for these questions but it will take a leader and a hierarchy to implement on the project.  Is that a viable for crowd sourced projects?  Only the future will tell I guess.

I am going to try a few of these and let you know how they turn out.

3D printing hits another milestone

Additive manufacturing also known as 3D printing is really starting to get amazing.  Several applications have started to impact how I do my job at the military aerospace level.

Firstly, 3D printing with metal that can be heat treated to high strength aerospace grade parts.

NASA recently used a technique called selective metal melting (SLM) with great success to build rocket motor components out of steel. NASA’s engineers have been able to produce parts with complex geometry only previously imagined, and with dimensional accuracy beyond that possible with traditional fabrication methods. http://www.extremetech.com/extreme/143552-3d-printing-with-metal-the-final-frontier-of-additive-manufacturing

The SLM process uses a high powered laser to fuse fine metal powders together layer by layer direct from CAD data to create functional metal parts. After each layer a powder re-coater system deposits a fresh layer of powder in thicknesses ranging from 20 to 100 microns. The SLM system uses commercially available gas atomized metallic powders to produce fully dense metal parts in materials including Titanium, Stainless Steel, Cobalt Chrome and Tool Steel. http://production3dprinters.com/slm/direct-metal-slm

Secondly, printing large complex structural components for aircraft composite bonded assemblies.

honeycombSandwich composites are innovative advanced materials. Adding a core between two facing skins increases stiffness dramatically over composite laminates while adding only a minimal amount of weight. Increasing the thickness of a sandwich composite part by a factor of two typically raises the stiffness by a factor of 12 and bending strength by a factor of 6.  Traditionally these cores have been fabricated flat and then bent and crushed to meet the complex profiles.  Going forward companies are looking to 3D print the ores with the profile and the honey comb cross section. This eliminates the potential for core crush and cell deformation while increasing the overall strength of the bonded panel. http://www.stratasys.com/~/media/Main/Files/Case%20Studies/Commercial/APAviradyneBusinessIndustrialEndUsePartsDDM.ashx

 

Additive manufacturing is or will be impacting just about every industry.  Here is a cool example I stumbled upon this week.  They are using 3D printed bone to repair a man’s skull.  Way Cool. http://urly.de/2c709

3-D printed skull

Skills

SKILLS & EXPERTISE

Project Management

–   Lead three multi-million multi-year projects

–   Lead teams with 1-8 direct reports and 6-40 indirect reports

–   Managed and been held accountable for budget, schedule and quality

–   Participated in hiring and firing activities

–   Taken over 30 hours of classes in leadership and management 

–   Working on adding a PMP certificate to my Six Sigma BlackBelt

Designer

–   18,000+ hours of Design experience.  500 hr Repair and Stress Analysis.

–   Software skills: Catia V5, Catia V4, Solid Works, PATRAN, NASTRAN, ABAQUS, Provision, ARIS, WordPress, Photoshop, Captivate, MS Office software.

–   Hands-on expertise with Product Lifecycle Management (PLM) tools: ENOVIA 6,000 hrs, Teamcenter Engineering 10,000 Hrs.

–   Requirements analysis, functional decomposition and allocation, systems synthesis & integration, verification and validation, systems analysis, and modeling and simulation.

–   Experience preparing & executing test plans/procedures from system requirements.

–   Ability to compile high quality commercial and government design packages.

–   Machinist: Mill, Lathe, CNC, and able to write G code for CAM tools.

Systems Engineering

–   Directly supported Program Managers, Chief Engineers and Chief Systems Engineers on the implementation strategy of the advance methods for systems engineering in a model based environment and the deployment of relational, parametric design.

–   Consumed customer delivery requirements to develop front-end standards and practices in design suit and stress analysis tools resulting in enterprise wide distribution of over 70 documents and videos.

–   Dissected FARs to create structures repair manual procedures for 787 cargo floor

–   Completed a masters in Systems Engineering and Quality

Fabrication

–   Created dozens of CAD/CAM solutions for medium and large CNC machines

–   Hand lay up of carbon, glass and Kevlar for test article and flight worthy repair

–   Machined high tolerance components with

–   Modeled, printed and assembled parts using various 3D Printers

–   Built several semi autonomous vehicles for various competitions

Integrated Scheduling / Planning

–   Created complex schedules with logic linkages tied to funding packages

–   Created work breakdown structures for several projects ranging from 3 discipline teams to 60 discipline projects

–   Completed critical chain analysis via CASPR and Microsoft Project

Manufacturing Engineering

–   Created dimensional analysis studies on assemblies ranging from 120 parts to over 300 parts

–   Documented assembly build plans, installation build plans and transportation plans

–   Created tool orders and job plans

–   Completed several dimensional analysis courses

Supplier Management

–   Initiated ROI, RFP and supplier selections on several large projects including the creation of supplier evaluation rubrics

–   Managed supplier technical interfaces and issue resolutions

–   Created supplier data management processes to secure export control and manage data revisions

–   Completed several courses on ethical supplier management