I’ve summarized some of my past engineering work and design projects here to provide a quick overview of my experience. Each item has a dedicated page examining the project in greater detail. For even more information, feel free to reach out to me at my email, sebastianbgraper@gmail.com.
Content List
Stanley Black & Decker
As a mechanical engineer on SBD’s Engineering and Advanced Technology team, I supported goals converting gas powered tools to battery power and proving the feasibility of novel technologies as applied to batteries and motors.
- Served as lead CAD modeler and manager of documentation across 10+ projects
- Created GD&T drawings with function-based datums and calculation-supported tolerances
- Collaborated with industrial designers to ensure the appearance of prototypes matched the existing DEWALT brand
- Worked jointly with machinists to improve manufacturability of prototype parts (standardized feature sizes, loosened tolerances, etc.)
- Scheduled and led mechanical design reviews, solicited input from electrical engineers
- Served as a reference on existing industry standards adopted by applications
- Assembling entirely novel and modified stock prototypes in site workshops
Tensile Creep Testing Frame
As my capstone engineering project at the University of Delaware, DuPont requested a scalable, reliable method to perform creep testing. Over three months I designed, fabricated, programmed, and documented the dead-weight frame shown on the right.
- Redesigned creep testing machines to improve reliability through use of dead weight force amplification
- Coded data acquisition program using LabVIEW to record sensor data based on operator-selected strain threshold
- Designed and machined custom sensor mounts for first-generation functional prototype using SolidWorks and CNC mill
- Produced a comprehensive user manual to guide system assembly, sensor setup, operation, and machine maintenance
Custom Vacuum Former
As part of my larger cosplay project, I designed and fabricated my own personal vacuum former after I was unable to get access to one locally.
- Designed functional solution compatible with household vacuum nozzle and oven size
- Produced MDF panel and 3D printed versions based on CAD model
- Created aluminum clamping frames using hand tools and stock hardware
Biomechanics Research
I spent the summer of 2022 refurbishing a custom micro indentation device for the University of Delaware’s biomechanics research department. I learned the LabVIEW visual coding language, basics of UI and test design, how to work with sensitive electronics, and how to read academic literature in unfamiliar fields.
- Successfully repaired a delicate machine with which I had no prior input
- Learned how to read unfamiliar, dense, technical literature (academic papers, electronics manuals)
- Installed electronics equipment including sensors, signal filters, and amplifiers
- Processed output data using curve fits to determine unknown material properties and produce graphs
- Produced documentation (lab notebook, user manual, experiment protocol) to pass my expertise along to other members of the lab
Pill Bottle Filling Machine
University of Delaware’s two-semester junior engineering project was to design, produce, and test a automated pill bottle filling machine. During the first semester our design concept was proven in low-fidelity materials, while the second semester focused on automating the mechanisms with sensors and code.
- Designed an automated system to fill 80ml square-based bottles with pill substitutes and tighten safety cap
- Manufactured custom parts using Stratasys 3D printer, Universal VLS4.60 laser cutter, and Cricut vinyl cutter
- Programmed system of stepper/servo motors, break beam sensors, LED indicators, and emergency stop button
Industrial Design/Prototyping Projects
Concurrently with the tensile test frame described above, I grew my prototyping and industrial design skills through a series of assignments focused on specific processes and materials. The course culminated in a hand tool redesign to improve performance, sponsored by Stanley Black & Decker.
- Created three prototypes focused on packaging, ergonomics, and personal protective equipment
- Learned low-fidelity prototyping techniques using foamcore board, hot wire cutters and polystyrene sheets, and tape
- Conducted qualitative research with tool end users, synthesized behavior and responses into actionable goals
- Created low and medium-fidelity prototypes of novel hand tool designs
- Quantified performance characteristics of hand tools using CAD motion studies and prototype testing
