Serj C.

IP67 Marine Electronics Case for Atlas Elektronik

Atlas Group • Freelance

Aug 2024 - Present • 1 yr 11 mos

Client & Goals: Atlas Elektronik required a highly durable, waterproof sheet metal enclosure to house sensitive marine sonar telemetry sensors. The casing had to withstand high humidity, saltwater corrosion, and severe structural vibrations while keeping a compact, modular footprint. Challenges: The housing had to be fabricated from marine-grade Stainless Steel (1.4404 / 316L). This material is highly prone to thermal warping and springback during CNC laser cutting and press brake bending if bend allowances are calculated incorrectly. Action: I designed a multi-part sheet metal enclosure incorporating correct bend radii and custom K-factors calibrated for the fabricator's specific tooling. I designed a custom compression-molded silicone gasket channel to guarantee an IP67 waterproof seal and integrated standard self-clinching PEM stainless steel fasteners. To minimize production risk, I manufactured and verified a physical functional prototype on my personal 3D printer, checking clearance fits and hinge movements. I then delivered laser-ready flat patterns (DXF) with clear bend lines. Result: Delivered a complete production-ready documentation package (STEP, DXF, and 2D PDFs). The fabricated stainless steel enclosures passed physical IP67 pressure testing and environmental shock testing with flawless sealing performance.

High-Precision Fixture for Rheinmetall

Volt • Freelance

Oct 2023 - Present • 2 yrs 9 mos

Client & Goals: Rheinmetall's manufacturing unit needed a robust, high-precision hydraulic clamping fixture to securely hold a complex cast steel component during automated multi-axis milling operations. The fixture had to guarantee repeatable workpiece positioning within a strict 0.02mm tolerance limit.Challenges: The raw casting had irregular, organic surface profiles. Standard vise clamping would distort the workpiece, leading to out-of-tolerance parts, while insufficient clamping force could cause catastrophic tool collisions during high-torque milling.Action: Using advanced German state-certified technician methodologies, I reverse-engineered the casting's organic mesh data and designed custom-contoured jaw inserts that perfectly matched the part profile. I integrated standard hydraulic swing clamps to apply consistent, uniform holding force. I specified hardened tool steel (1.2379 / D2) with a 58-60 HRC heat treatment, and generated fully dimensioned 2D DIN/ISO engineering drawings with tight geometric tolerances (GD&T) for the toolmaker.Result: The fixture was machined, heat-treated, and deployed on the production line. It successfully reduced workpiece setup time by 65% and achieved a 100% success rate (zero scrapped parts) over a 1,000-unit production run.

Aerospace Bracket CAD & DFM for Airbus Assembly

Airbus • Freelance

Jul 2023 - Present • 3 yrs

Client & Goals: The structural assembly division at Airbus required a complete engineering redesign of a lightweight aluminum bracket used in internal cabin cable routing. The goal was to reduce the part's weight by 15% while ensuring it could be CNC machined from a single block of Al 7075-T6. Challenges: The original CAD model featured deep internal pockets and sharp corner fillets. This geometry risked severe tool chatter, tool deflection, and excessive machining cycle times on standard 3-axis CNC milling centers, significantly driving up manufacturing costs.Action: Leveraging my German technical training (Maschinenbautechniker), I conducted a thorough DFM (Design for Manufacturing) audit. I remodeled all internal pockets to allow tool access using a standard 8 mm end mill 4.0 mm. I optimized the pocket depth-to-diameter ratio to a rigid 3:1 limit to prevent tool deflection. Finally, I adjusted the tolerancing to ISO 2768-m and prepared detailed 2D blueprints using strict GD&T (ASME Y14.5) to ensure repeatable quality inspection.Result: Delivered CAM-ready STEP models and fully toleranced 2D blueprints. The optimized design reduced CNC milling runtime by 22%, cut material weight by 18%, and passed physical assembly verification with zero defects.