Work Samples | portfolio

Alta Project samples

Below are a few samples of my design projects at Alta. I lost access to my computer soon after the company folded, but I did obtain a few pictures of finished or in-progress projects.

Return to the Alta Motors home page for more details on the company and my experience there.

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Battery Carrier Cart

Inverter Leak Test

The inverter leak test was used to ensure the inverter was watertight by measuring the decay rate of air pressure in the pressurized inverter. The fixture involved a modified inverter lid, a platform with an air inlet that allowed for a tight seal when clamped, and a series of clamps. Contact materials and clamp locations were a few of the key design concerns. Creating a tight and easily attainable seal proved challenging.

Cell Press Calibration Block

This calibration block was for calibrating the height of the plungers on the battery cell press. The cell press was a complex machine used for gently pressing the individual battery cells to equal heights within the battery pack section. Calibration was important because having the cells perfectly level allowed for much more consistent sodering of the cells during the bonding process.

Cell Press Scanner Mount

This scanner mount allowed for a barcode on the battery pack to be read, triggering automatic advancement of the order in the MES system. The scanner needed to be perfectly alligned for reading the barcode, so it needed an adjustable angle. The mount not only needed to fit in a tight area, but also needed to look good as part of a showcase machine.

Battery Cell Cart

I designed this cart for transporting boxes of lithium ion battery cells. The major design concerns were center of gravity location and maximizing stability, ensuring the carts would not tip and dump the highly combustable cells. The design had angled conveyors for easy loading/unloading and considered Osha height standards for lifting. The first cart was ready for assembly on Alta's last day.

MES Interface Phone & Charger Mounts

My 3D printed phone and charger mounts were used all along the battery and bike assembly lines. The phones were used as the technician interface to the MES system. These mounts prevented the phones from falling and breaking, and supported 5S principles.