The Context
While the overarching objective of this project was to integrate advanced vision and motion control algorithms for laser micro-processing, software algorithms are entirely dependent on rigid, precision-engineered physical foundations.
My core responsibility was to bridge the gap between digital control and physical fabrication. I engineered the optomechatronic infrastructure and mechanical workstations required to make sub-micron laser precision possible, ensuring seamless interoperability between physical stages, sensors, and controllers.
Mechanical Design & DFM
To support the integration of advanced laser sub-systems and establish a mobile testing environment, I spearheaded the end-to-end design of a custom Movable Laser Workstation.
- Complex Assemblies: Utilised SolidWorks and Autodesk Inventor to design a highly rigid 4040 HFS aluminum profile cart capable of supporting >200kg dynamic loads, establishing strict mechanical mates and component clearances.
- Design for Manufacturing (DFM): Generated precise 2D manufacturing drawings specifying exact hole patterns, countersunk clearance dimensions (e.g., M6 drop-in hardware), and structural fillet tolerances.
- Supplier Liaison: Managed technical procurement by translating engineering requirements to overseas fabrication suppliers via Taobao, ensuring CAD models were accurately interpreted for physical CNC machining.
Mechanical CAD Transition: Highly constrained isometric render of the 5-tier 4040 aluminum profile workstation, designed to isolate vibrations for sensitive laser hardware and negotiate overseas CNC fabrication.
Next: Optomechatronic Hardware Integration
Beyond the mechanical chassis, I was tasked with the physical and electrical integration of the multi-axis motion stages and galvanometer scanners.
- Hardware Overhaul: Physically prepped and mapped electrical connecting cables to upgrade the JDX 5-Axis machine's legacy controllers to advanced Elmo motion control drives (Titanium Maestro).
- System Architecture: Decoded complex installation manuals to map out the dual-motion synchronization between the SPiiPlusEC (motion controller), syncAXIS (physical stages), and RTC6 (laser scanner).
- Documentation: Drafted a comprehensive [5-AXIS Curved Surface Laser Micromaching Handbook] Standard Operating Procedure to centralize the newly mapped protocols for future engineers.
Optomechatronic Integration: Physical overhaul of the JDU JDX 5-Axis machine, involving intricate electrical pin mapping and controller upgrades to Elmo Titanium Maestro for synchronized operations.
Ongoing: Laser Operations & Quality Control
Operating high-power industrial lasers requires zero margin for error. I actively participated in the testing, logistics, and quality assurance of the laboratory's optical hardware.
- Laser Calibration: Set up and safely tested Class 4 industrial lasers (LUXINAR E25-9.3 CO2 and GLPN-500-12-75M) under strict laboratory safety protocols.
- Microscopic Inspection: Conducted critical quality control on fragile Quartz Block Head (QBH) fiber optic connectors using a monocular microscope, inspecting for micro-contaminants that could cause catastrophic window failure.
- Logistics: Coordinated the physical packaging and international RMA logistics for high-value optical hardware, calculating volumetric costs and ensuring safe transit to regional offices.
Controlled Laser Operation: Testing the LUXINAR E25-9.3 CO2 industrial laser with integrated power measurement, demonstrating strict adherence to Class 4 safety protocols.
High-Power QC: Microscopic inspection of high-value Quartz Block Head (QBH) fiber optic connectors, a critical quality check to prevent catastrophic window failure.
Key Takeaways
This experience reinforced that true engineering happens at the intersection of disciplines. By actively participating in every step, from designing SolidWorks models and negotiating with external manufacturers, to mapping electrical pins and inspecting fragile optical fibers, I gained a holistic view of how complex optomechatronic systems move from concept to deployed physical products.