3D printed ultrasonic welding rails for plastic welding. A large welding block horn moved downwards into the nest to weld two injection molded components together. Rail dimensions were constrained by high and low mating dimensions from positional tolerance and injection molding volume variability. Rail contains slots to avoid over-dimensioning and slop during installation.

Automated force gauge test rig for pin bending verification. Used this to verify change in applied stress needed until failure met design inputs.

Instrument with a clamped fluidic cartridge. Contains a one-off, clear laser-cut  window to visualize flow. Was used to tune and diagnose possible foaming with flow rate values collected externally.

Laser welding jig with removable acrylic bumpers and a custom top slot for welding plastics. Installed on a machined sliding drawer. Used this to test out weld methods for new parts.

Test jig for measuring flow rate for any set pressure. Driving air pressure set on the left device with a flow meter in series. Arbor press on the right used to clamp plastic flow cartridges to reproduce flow. Used this for failure investigations for flow clogs, interruptions, leaks, etc.

Handheld buffer volume measurement tool for rapid buffer filling measurement. Was used to double-check manufacturing fill specifications.