Derek M Siems Design/Engineering Portfolio 3/13

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March 08, 2013

Derek M Siems Design/Engineering Portfolio 3/13



March 08, 2013


  1. Derek M. Siems BSME Design and Engineering Portfolio

  2. Derek M. Siems BSME Section 1: Professional Engineering Design Work
  3. Design/Engineering Phantom 65 Remotely Controlled Lens Cap The Phantom 65

    Remote Lens Cap is a quintessential example of solving a problem “due yesterday”. This lens cap was needed to black-balance the Phantom 65 IMAX-sensor-sized high- speed digital cinema camera while it was mounted to a helicopter for a special shoot. The cap had to completely seal out all light when closed and be completely outside of the 180º viewing angle when retracted… and do so completely by remote on a moving helicopter in Canadian winter weather with two weeks of development time. This obstacle was overcome by designing a custom direct-digital-manufactured FDM-style 3D printed cap powered by a Heden high-torque remote follow-focus motor. The cap performed flawlessly. Primary Material: 3D Printed FDM ABS Plastic Credits: AbelCine logo property of AbelCine, Inc.; Phantom 65 Model property of Vision Research Designed for:
  4. Phantom Miro Rigging Accessories Credits: AbelCine logo property of AbelCine,

    Inc.; Phantom Miro Model property of Vision Research The Phantom Miro is a compact high-speed digital video camera from Vision Research primarily intended for industrial scientific markets. Because the Miro wasn’t originally intended for entertainment use, there were many functional elements required to make the Miro perform to professional camera operator standards. The following pages will highlight the features of each major element of this rigging kit. Design/Engineering Designed for:
  5. I-Plate “Cheese Plate” The I-Plate is what’s known to the

    professional camera industry as a “cheese plate” because of the many threaded accessory holes resembling a slice of Swiss cheese. This cheese plate was designed to have a contoured, symmetrical design to be used on the top and bottom of the camera interchangeably. ¼-20 camera accessory holes on the side of the I-Plate become a 4.375” square when two plates are used, which allows for multiple orientations of the included accessories. The I-Plate cheese plate is what enables the mounting of all other Miro accessories. Primary Material: Machined Aluminum with Type III Hardcoat Anodizing Credits: AbelCine logo property of AbelCine, Inc.; Phantom Miro Model property of Vision Research Design/Engineering Designed for:
  6. Miro Top Handle The Phantom Miro Top Handle is a

    multi-configurable filming grip capable of accommodating a number of filming scenarios. As seen to the right, the handle can be deconstructed to only the bare essentials needed, thus saving weight and reducing user fatigue. The many mounting holes accommodate bolt-on camera accessories as well as enable the camera to be mounted under an object with adequate spacing to allow for lens clearance. The other mounting points allow for the remainder of accessories such as the “cold shoe” for popular DSLR camera accessories and the 15mm rods for lens-related add-ons. 15mm Accessory Rod Mounts 1/4-20 and 3/8-16 Accessory Mounting Holes Start/Stop Record Button (Trigger) Ergonomic Contours (most features are made in one process on a 4-axis lathe) “Cold Shoe” Accessory Mount Primary Material: Machined Aluminum with Type II and Type III Hardcoat Anodizing Credits: AbelCine logo property of AbelCine, Inc.; Phantom Miro Model property of Vision Research Design/Engineering Designed for:
  7. X-Grip The X-Grip is a shining example of the marriage

    of DDM (Direct Digital Manufacturing) and ergonomics. The X-Grip can be rotated into any orientation about its equally-spaced mounting holes to accommodate the holding position most pleasing to the user. The smooth, flowing curves reduce localized pressure on the user’s fingers and the “X” shape allows the user to wrap his or her fingers around part of the grip for added stability. The off-the- shelf screws and spacers allows the user to inexpensively accommodate many different offsets depending on the operator’s preference. Primary Material: 3D Printed FDM ABS Plastic Credits: AbelCine logo property of AbelCine, Inc.; Phantom Miro Model property of Vision Research Design/Engineering Designed for:
  8. Miro Breakout Box Interlocking Teeth Video Out/ Trigger (depending on

    model) DC Accessory Output Remote Control Input DC Input Snub Bushing for Camera Connector The Phantom Miro Breakout Box is a power and signal breakout box designed to separate signals from a single connector into multiple, more standard connectors as well as enable the camera to be powered by a more common DC input connector. The enclosure was designed to minimize occupied space as well as put the connectors in the ideal position with respect to the other components used on the camera. To simplify assembly, interlocking teeth were used on one side of the enclosure and are further secured with the snub bushing. Primary Material: ABS-Like Cast Urethane Credits: AbelCine logo property of AbelCine, Inc.; Phantom Miro Model property of Vision Research Design/Engineering Designed for:
  9. “Rosette” Bar and Custom Handgrip The “Rosette” Bar is a

    simple aluminum bar that enables traditional Arri® “Rosette”-style handgrips to be used with the Miro camera, thus enabling the use of a number of legacy handgrips. The handgrip shown is a concept based on the famous Aaton S.A. handgrip that was designed to be manufactured by a Roland 4-Axis CNC Lathe rather than using the time consuming and expensive process used to hand-carve the Aaton S.A. handgrip. Primary Material: Machined Aluminum with Type II Anodizing; CNC Machined Walnut Credits: AbelCine logo property of AbelCine, Inc.; Phantom Miro Model property of Vision Research Design/Engineering Designed for:
  10. Miro Cine Riser The Phantom Miro Cine Riser is an

    adapter plate that allows the Miro to be used with a host of cinema mounting options. The bolt pattern on the bottom is designed for the popular Arri® bridge plate and gives the same distance from base to lens center as Arri® cameras. This riser also adds 15mm accessory rods and Arri®-style rosettes for handgrip mounting options. Another interesting feature of this riser is that the lower portion can be used with different top plates for use with other cameras, minimizing the number of complex custom parts needed to outfit different cameras. Primary Material: Machined Aluminum with Type III Hardcoat Anodizing Credits: AbelCine logo property of AbelCine, Inc.; Phantom Miro Model property of Vision Research Design/Engineering Designed for:
  11. ProVFM Viewfinder Adapter The ProVFM Viewfinder Adapter enables camera operators

    to use a Sony or Panasonic broadcast-style high-definition viewfinder on the Sony PMW-F3 digital cinema camera. This feature enables “run and gun” camera operators, like documentary and sports filmers, to more effectively use the popular and cost-effective PMW-F3 camera. Primary Material: Machined Aluminum with Type II Anodizing Credits: AbelCine logo property of AbelCine, Inc.; Sony PMW-F3 wireframe property of the Sony Corporation Design/Engineering Designed for:
  12. ProVFM Manual Artwork The ProVFM Viewfinder Mount Kit Manual is

    a basic user assembly and use guide for the aforementioned ProVFM Viewfinder Adapter. These assembly and use diagrams are meant to visually instruct the user how to operate the ProVFM far better than normal written instructions. Note: Only the illustrations are the work of Derek M. Siems; text and layout are by AbelCine Assembly Illustration Design Credits: AbelCine logo, text, and general page layout property of AbelCine, Inc.; Sony PMW-F3 wireframe property of the Sony Corporation Designed for:
  13. Offshore Oil Rig Removal and Environmental Restoration Equipment Heavy-Industry Engineering

    As an assistant engineer at Mech-Tech Engineering, I aided in the creation of several offshore oil rig “plug and abandonment” tools to remove drilling rigs and restore the environment to its original state. Some of these tools included a sub-sea drill casing mill cutter, an industrial saw for cutting drill casing into manageable lengths, hydraulic control panels, work platforms, and other various projects. My contributions to these projects included structural and kinematic design, solid modeling, finite element analysis (FEA), and print detailing. Credits: Mech-Tech logo is property of Mech-Tech Engineering, LLC. All pictured equipment is property of Mech-Tech Engineering. Primary Material: Flame Cut Steel; Water Jet Cut Stainless Steel Designed for:
  14. Derek M. Siems BSME Section 2: Independent Design Work Credits:

    Shotgun, cog, and wing nut are sourced from Google Images.
  15. Ergonomic Design “Rad Pad” Ergonomic USB Controller Inspired by: Credits:

    Nintendo logo and NES controller design are property of Nintendo Co., Ltd. This ergonomic USB controller is a re-imagined design of the controller for the 1985 Nintendo Entertainment System. Starting with the internals of a USB remake of the original controller, the directional pad, buttons, and controller shape were all reworked to increase comfort and performance. The end result yields more responsive controls and lower user fatigue during extended gameplay. Note: some injection molding conventions such as draft and max rib thickness were waived in favor of functionality when printed on a home 3D printer. Original 1985 NES Controller
  16. Machine Design! All-Machined Drum Bass Pedal! The Drum Bass Pedal

    was designed as an all-machined alternative to traditional cast drum bass pedals to demonstrate machined aluminum design capabilities. All parts of this bass pedal can be created using conventional CNC technology or are available as off-the-shelf parts. Also featured is a sample of a print that would be used by a CNC machine shop to manufacture and perform quality control checks.!
  17. Ergonomic Design! Brass Knuckle Skateboard Grip! As skateboarding becomes a

    more viable method of transportation in dense cities like New York, the fact that there is no particularly comfortable way to hold a skateboard when carrying it around quickly becomes apparent. ! To solve this problem, the form of brass knuckles was used as a basis for this skateboard carry handle, a design that inherently has high levels of user control and has aesthetic ties to both the punk rock and hip hop culture of skateboarding. ! Realizing that injection molding would be required to meet an acceptable price point, this grip was designed with considerations for draft, parting lines, lack of undercuts, etc. to ensure a straightforward and cost- effective mold could be produced.! This flow simulation demonstrates the projected flow of plastic into an injection mold cavity.!
  18. Aesthetic Design! “Brick Man” Military Hats! These “brick man” hats

    were designed to resemble a modern military beret and garrison cap for use with Lego-style construction brick figures.! Credits: Lego is a registered trademark of Lego Group and is in no way affiliated with Cohesive Product Development LLC
  19. Ergonomic Design! iPhone 4/4S Sleek Case! The iPhone 4/4S Sleek

    Case was designed as a protective case that offered a clean, minimalist option to iPhone owners. ! This case features a full-perimeter bumper with a lip on the top and bottom to prevent direct contact in the event of a drop. While the Sleek Case offers excellent protection, it doesnʼt inhibit use of the touchscreen nor does it mask rear glass panel. Additionally, this case adheres to Appleʼs recommended camera cutout specs and features a guard that prevents accidental finger smudging of the lens while holding the phone.! The iPhone 4/4S Sleek Case is the perfect combination of protection and usability.!
  20. Ergonomic Design Spatula Knife Concept This spatula knife concept is

    heavily inspired by the legendary OXO Good Grips line of kitchen and home improvement tools. Born out of the frustration of constantly needing to switch between a knife and a spatula while cooking, this tool combines both functions by modifying a typical spatula with sharpened edges, torque equalizing thumb grips to counter the blade offset, and semi-flat sides on the handle for additional torque resistance. These features combine to make a fully functional spatula that can be used to cut butter, cheese, fruits, vegetables or other relatively soft items that are typically cut into small pieces and then lifted by a spatula. Credits: OXO and Good Grips logos and packaging design template are property of Helen of Troy Limited Inspired by:
  21. Ergonomic Design Gallon Size Gatorade Bottle Concept Nearly all gallon-sized

    liquid containers are difficult to lift and create awkward wrist positions while pouring; thus, this container was created to remedy these ergonomic issues. The ambidextrous design has the user first grab the bottle under the cap ring and then tilt the container using the pronounced grip at the bottom. If needed, the bottle is capable of being pressed against the chest of the user like a rifle stock for a third point of stability. This design also benefits from a rectangular footprint to maximize shelf space, a mid-bottle lip that creates turbulent flow to mix the beverage as it is poured, and has the aesthetic appeal of resembling an inverted Gatorade® lightning bolt. Credits: Gatorade lighting bolt logo is property of PepsiCo, Incorporated Inspired by:
  22. BMW M3 Shift Knob Concept Ergonomic Design The BMW ///M

    series represents the pinnacle of German sport and luxury synthesis, thus, this shift knob combines a form-fitting shape with a striking arc that both ties together the design schema of the M3 and provides a stabilizing grip to properly position the hand and prevent rotational slippage if the hand becomes sweaty during intense driving conditions. Credits: BMW and ///M Logos and stock M3 interior photo are property of Bayerische Motoren Werke AG Inspired by:
  23. Cold/Low Normal/Good Hot/High Dynamic Color Feedback System Concept Off Interaction

    Design Race drivers rely on constant instrument feedback to prevent engine damage during a race; however, reading a needle and tick marks is difficult and dangerous in intense situations of speed and handling. This system utilizes the already present multi-color backlight system of Auto Meter gauges to indicate the status of various engine parameters via user set conditions so that the driver can more easily identify impending engine problems. This system could also be used for tachometers to indicate that the car is approaching redline or make its way to standard cars and combine with GPS data to indicate that the car is traveling within a few MPH of the posted speed limit. Danger (flashes rapidly) Credits: Auto Meter logo and instrument design are property of Auto Meter. Stock blurred racecar dashboard photo is sourced from Google Images. Inspired by:
  24. Aesthetic Design Credits: Swatch Logo is property of The Swatch

    Group Ltd. Tachometer Watch Concept The tachometer watch is an understated novelty piece intended to appeal to motorsports enthusiasts. Unlike a standard watch that moves in a constant clockwise fashion, this watch imitates the action of a tachometer by moving clockwise for 55 seconds and then reversing for 5 seconds like a race car accelerating and decelerating as it laps a track. The lower right section has a clock and date in the same position as you would find on a real automobile dashboard and thus makes the watch a fully functional time piece as well as drives home the design inspiration. Inspired by:
  25. Aesthetic Design Wine Glass Bar Stool Concept This wine glass-inspired

    bar stool combines an inherently strong and comfortable shape with an inseparable association with upscale alcoholic beverages. The three-piece construction makes the stool easier to manufacture, ship, and assemble (the pieces simply screw together with no tools needed) as well as being capable of modular replacement if a component is ever damaged. The metal sub frame under the plastic exterior ensures even the heaviest or rowdiest of bar guests will have a tough time damaging this stool. Lastly, the smooth contours with no bolts or crevices makes it easy to hand clean or even hose down after a night of spilled drinks, making it a great outdoor bar stool as well. Credits: Calligaris logo is property of Calligaris s.p.a. Stock bar photo is sourced from Google Images. Inspired by:
  26. Reconfigurable Task Chair Concept Aesthetic Design This convertible task chair

    concept combines the function of a standard office task chair with that of a kneeling chair. The chair would remain with the seat back “up” for quick sessions or reclined seating and convert to a kneeling chair when the user needs to lean over a desk or drawing table for extended periods of time. The 2-in-1 nature with quick conversion affords the user the privilege of not having to face the ergonomic consequences of not having the appropriate seating style at all times. To ensure ample comfort, the seat cushions would be comprised of a sandwich of three different foam densities (softest near surface, hardest near frame) so that the flat surfaces create custom molds to every user of the chair. Credits: Calligaris logo is property of Calligaris s.p.a. Inspired by:
  27. Aesthetic Design Tubular Garment Rack Concept This tubular garment rack

    concept is an exceptional combination of simplicity, elegance, and inherent strength in one easy-to-manufacture product. Unlike dull industrial racks, this rack celebrates the garments and makes the combination of the two into an almost sculpture-like display piece. Ideally, the rack would be created with mandrel bends and used for a premium market of high end retail and consumer use, but could also be made with crush bent tubing or sold as segments to be bolted together for lower end markets. Credits: Calligaris logo is property of Calligaris s.p.a. Stock clothing photo is sourced from Google Images. Inspired by:
  28. Derek M. Siems BSME Section 3: Other Skills Credits: CNC

    milling machine diagram sourced from Google Images.
  29. Re-imagined Art The “Dead Bunny Cupcake” 3D printed sculpture was

    commissioned by a New York artist in order to have a smoother, more consistent variant of the clay- based sculptures pictured in the top- left. A mass-produced version of this model is in the works as an “urban vinyl” art toy. Credits: Dead Bunny Cupcake clay sculptures and conceptual idea property of Loren Siems Primary Material: 3D Printed FDM ABS Plastic Aesthetic Design
  30. 2D 3D Transcription The Futurama Planet Express Ship is a

    fictional space ship from the popular television show Futurama. This variant of the P.E.S. was designed with exaggerated features and multiple parts to accommodate use with low-cost home 3D printers. The model was donated to the Thingiverse 3D printing community for 3D printing enthusiasts to enjoy for free. Credits: Futurama and the Planet Express Ship are the property of Fox and the Curiosity Company. Thingiverse is property of Makerbot Industries. Model is strictly for non-profit use. Primary Material: 3D Printed FDM ABS Plastic Aesthetic Design
  31. Mill and Lathe Work The hydraulic jack (left) and pecan

    cracker (right) are projects created as undergraduate work at the University of Louisiana at Lafayette. Both projects were created using aluminum and brass under the guidelines of manufacturing prints. The pecan cracker was created with a manual mill and lathe and hand polished. The hydraulic jack was created with CNC mill and lathe machines using code generated by GibbsCAM software. Note: these projects were created using pre-existing design prints and are not representative of the design methodology of Derek Siems. Credits: University of Louisiana logo is the property of the University of Louisiana at Lafayette. Machining
  32. Electrical Prototyping This project was centered around finding a method

    to determine the concentration of a two-phase flow liquid without direct visual observation. The system works by using a capacitance-based circuit to determine the concentration of liquid and gas (water and air, respectively) by metering the current flow through the tube. By using additional software to convert the analog signal into a digital “good” or “bad”, this system could be used to monitor boilers or places likely to have cavitation issues. Credits: University of Louisiana logo is the property of the University of Louisiana at Lafayette. Electrical
  33. Design Sketching Sketching While it is my preference to bring

    an idea immediately from my brain into Solidworks to further refine it, I understand the need for conceptual sketching during discussions of ideas to agree on a basic premise. So, this quick sketch work is an example of what I would produce when conceiving my Gatorade® bottle design to communicate with co-workers. This concept’s main inspiration was a pump action shotgun. Shotguns have retained the same form for over a century due to its ability to finely stabilize a heavy object. Much like when shooting a target, a person pouring a beverage needs stability and comfort to pour a beverage without spilling or strain. My first concept seemed too literal and might conjure up negative constructs of violence, thus, I smoothed out the neck to a more traditional “milk bottle” form and also widened the hand grip to encourage a “cradling” gesture, which was more appropriate for the wide form, while retaining the intended 3 points of stability found on the shotgun. For the bottle cap, I wanted to do away with the horribly uncomfortable standard ridged bottle cap. My first idea was to make an ergonomic cog cap, but when rendered it appeared too bulky and thus expensive to make. So, instead, I looked to the simple wing nut design to create a similar ergonomic concept, but with a lower cost to manufacture. Credits: Shotgun, cog, and wing nut are sourced from Google Images.
  34. Legal and Credits All works in this portfolio are understood

    to be created solely by Derek M. Siems unless otherwise credited. All company logos are the property of their respective companies and no affiliation or endorsement is implied. The utilization of company logos and design schema in conceptual models is to demonstrate the abilities of Derek M. Siems in the constraints of existing company design precedent. All conceptual solid models are the sole creation of Derek M. Siems and were created using Solidworks by Dassault Systèmes Corp. All photographic simulations were created using original or stock images (where credited) with the open source GIMP software (Photoshop equivalent). The contents of this portfolio are only intended to be distributed amongst design management staff to an end of gainful employment. Public distribution is forbidden without permission and proper citation. Any questions, concerns, or publishing permission requests regarding the contents of this portfolio may be discussed via e-mail at All original works ©2010-2013 Derek M. Siems unless otherwise cited