XponentialWorks & Nexa3d
July 2019 - April 2021
XponentialWorks is a venture investment, corporate advisory and product development company, specializing in Artificial Intelligence, 3D printing, robotics, and the digital transformation of traditional businesses. I worked as the Additive Manufacturing Engineer for Xponentialworks.
I operated a variety of additive manufacturing machinery, perform R&D projects for early stage tech companies, and design parts using standard CAD, generative design, and organic modeling software for a variety of clients and start up companies (including Apollo Robotics, NXT Factory, Nexa3D and the XPRIZE Foundation).
Additionally, I was the applications engineer and Product Owner for NEXA3D. This includes designing sample and customer parts, writing case studies, operating several NXE400 machines in our AppLab, creating user guides, working closely with all the teams to troubleshoot user issues, and going on-location around the world for installations and training. I was also the Product Owner for Software, and led the release of both hardware printer firmware, and a full market release of the NXE400's slicer software.
For my first project, I worked with an artist to design, 3D model, and additively manufacture the Moonshot Award Trophy as part of the Lunar Xprize competition. This trophy was received by team SpaceIL for their efforts in sending their Beresheet rover to the moon.
The final trophy before being shipped out.
At the Xprize Visioneering ceremony
To create the trophy, I first received some 2D-sketch from artist Jim Todd. We reiterated several times using the renders and options I gave to him, to finalize on the design. The moon was 27% the size of the earth and the earth's axis was 23 degrees, as is reality. A combination of Solidworks, Meshmixer, Blender, and Materialise RP was used to complete the final design. This was then 3D printed in Nylon SLS (24k gold plated for the orbit), and has a laser-cut wooden base beneath.
Initial given sketch
Sketch of trophy with some dimensions
Initial render. After this, Jim sent another sketch that you can see within the documents I sent him (below).
Trophy Design 2.pdf
This was the final photo-realistic render / design we decided on before being manufactured.
SLS printed trophy components
Gold plated orbit and globe. (The moon was then spray-painted gray, and the base had car coating)
Me applying some finishing touches before shipping it out
XponentialWorks partnered with Arcimoto, an Oregon-based transportation innovator, to produce 3D print lightweight suspension components for Arcimoto’s Fun Utility Vehicle (FUV).
I used ParaMatters generative design software CogniCAD, in combination with Solidworks, to redesign the steering knuckle for the upper control arm of the FUV seen below. This part was then additively manufactured using an EOS EOSINT M 280 industrial metal 3D printer. and then installed onto the vehicle. Learn more about the rest of the project here and here. Another article is here.
The steering knuckle that I helped optimize. There was a 40% weight reduction, while maintaining equal strength.
As part of Nexa3D marketing, I was the designated actor and voice over guy for a variety of hardware product and resin videos.
As part of the XponentialWorks portfolio, I work very closely with Nexa3D for a variety of projects, and wear many hats. I am the Applications Engineer, as well as part of the customer service team. On a daily basis, I work with all the teams from marketing to mechanical engineering to find solutions to problems that arise.
Some of the places I have traveled doing training, installations, and demos on Nexa3D's products
Helping out one of our re-sellers on the East Coast with a live demo of the NXE400 machine
I also presented every so often on several topics including the 3D printing slicer I helped develop
Besides doing installs and working with customers for their solutions, I designed many of the sample parts used for our Nexa3D's marketing material. Below are some of the parts that I designed and printed on the NXE400 machine and on the XiP printer. They are all used for sample parts, for demos, and for marketing material. I used a combination of Solidworks, Blender, Meshmixer, and Materialise to design these parts.
I designed nasopharyngeal (NP) swabs as part of the response to fight COVID-19. All were made in accordance to NP references online, and designed in Solidworks + Blender + Meshmixer.
I also came up with and designed a hybrid scraper-lattice NP swab. This was done using the Tissue add-on for blender
Here they are after being printed in a bio-compatible resin on an NXE400 machine
Here they are being mass printed during R&D on the NXE400 printer
Flexible Factory
As part of Nexa3D's efforts to combat COVID-19, I was a crucial element of the Flexible Factory that we set up. I was in charge of all the print files and models we were to print, using different versions of our proprietary slicer software for each printer. Multiple trials were done to make sure we have the file that would be the fastest print, as well as the easiest to process. I was also one of the two engineer operators of the FF, leading to the successful completion of over 2,000 faceshields in 2 weeks.
Additionally, I create a lot of the marketing material required for all our promos. This includes renders of 3D models for poster designs, as well as sample part kits that I helped with, including the laser cut pattern for the foam, using the software Blender + Gimp.
I designed this tree of supports so that you can array multiple models on the same build for 3D printing