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Project Portfolio Kyle Estenger 34655 Arroyo Rd, Lake Elsinore, CA 92530 (951) 252-4654 [email protected] 1/8

Kyle Estenger Project Portfolio 9prjcts

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Page 1: Kyle Estenger Project Portfolio 9prjcts

Project Portfolio

Kyle Estenger

34655 Arroyo Rd, Lake Elsinore, CA 92530(951) 252-4654

[email protected]

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Page 2: Kyle Estenger Project Portfolio 9prjcts

Table of Contents

Personal Projects

CNC Mill 3

Electric Tricycle 4

Chainsaw Motor Driven Bicycle 5

Carbon Fiber Skateboard 6

Spot Welder 7

Academic Projects

Foldable Surfboard Fin 8

Northrop Grumman: CubeSat Deployable Solar Array 9

CNC Mill

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Page 3: Kyle Estenger Project Portfolio 9prjcts

The CNC Mill project was largely motivated by my desire to have this as a tool. This project required meticulous attention to detail because so many of the dimensions for hole locations had to be accurate to ensure machine accuracy. This is by far my favorite project as represents my interests and motivations well. The 3-axis mill achieves translational motion using stepper motors, lead screws, and linear bearings. The spindle is a DC motor controlled with PWM. The stepper motors are controlled using and Arduino motherboard and a GRBL daughterboard. This allows for the interpretation of G-code and the amplification strong enough to drive the stepper motors.

Electric Tricycle

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Page 4: Kyle Estenger Project Portfolio 9prjcts

The Electric Tricycle project includes a 24V DC motor controlled by a high amperage momentary switch. The tricycle has a belt driven one wheel drive transmission. I used this to get groceries and ride to class. The tricycle has 2 12V Lead Acid Batteries in series.Chainsaw Motor Driven Bicycle

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Page 5: Kyle Estenger Project Portfolio 9prjcts

The Chainsaw Motor Driven Bicycle project was initially intended to replace the need for my normal bicycle, but I was quickly told not to ride this loud 2 stroke motorized bike on campus. The transmission is direct drive off of the rear tire using a peg that is textured to grip the tire. This was the most simplistic way to achieve the very small gear ratio that I needed.

Carbon Fiber Skateboard

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Page 6: Kyle Estenger Project Portfolio 9prjcts

The Composite Skateboard project was driven by my desire to make a lighter skateboard. I felt that wood skateboards were not optimizing strength to weight. I was able to decrease weight of the skateboard by about 30% while maintaining a comparable resistance to fracture under similar loading conditions. The difficult aspect of a wooden skateboard to compete with was its toughness. Delamination of my composite skateboards occurred under loads tangent with fiber directions.

Spot Welder

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Page 7: Kyle Estenger Project Portfolio 9prjcts

The Spot Welder project was motivated by a need for a spot welder. I was making a steel enclosure with sheet metal and I thought that this would be a handy tool to do said job. The welder is very simple. It is based off of a microwave over transformer where I removed the secondary winding and replaced it with my own secondary winding which is 2 loops of 1 gauge copper wire in order to achieve metal melting amperage.

Foldable Surfboard Fin (Team Project)

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Page 8: Kyle Estenger Project Portfolio 9prjcts

The Foldable Fin Project was a 1-quarter (3 month) project in which each group was expected to come up with an innovative solution to a problem. Our group decided to address the difficulties associated with transporting and storing surfboards due to the awkward geometry of the fin.Video Link: https://www.youtube.com/watch?v=Dgvor-Iz1GwNorthrop Grumman: CubeSat Deployable Solar Array (In Progress)

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Page 9: Kyle Estenger Project Portfolio 9prjcts

For this project I have been tasked to design a deployable solar array for a small satellite that will be capable of deploying and solar tracking. This project includes unique design solutions to thermal, mass, mechanical, vibrational, structural, and atmospheric problems. In this project I have designed the mechanisms and functionality of the mechanism, analyzed the design against strict design requirements, and I am now machining, assembling, and testing the Satellite Solar Array. This project has bee the most thorough engineering project I have been involved with.

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