Projects
Below are a few examples of Exact Engineering’s projects.
Click here for a list of consulting projects.
All-Optical Electrophysiology Microscope
This exciting technology was developed at Harvard University for drug discovery in neurounal and cardiac diseases.
This project entailed:
- Optical design of the laser illuminated imaging system.
- Optomechanical design of the optics bench, optical train and custom optic mounts.
- Vibration isolated optical bench.
- Optomechanical design of a 1 micron resolution focus and sample actuators.
- Detail manufacturing drawings and complete fabrication.
- Optics alignment and bonding.
- Assembly and delivery of the completed system.
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Waste Heat Recovery System
Our client developed a novel highly efficient thermal dynamic cycle for use in waste heat recovery systems. The system makes use of waste heat and converts it to electrical energy by driving a generator with a heat engine. The system was comprised of a heat engine, a generator, a containment vessel, two heat exchangers and a high pressure (725 psi) and high temperature (325 F) plumbing and valving system.
For the engine, we started with the short block of an inline four cylinder diesel engine (engine block, pistons, crankshaft and oil pump). All other stock components were removed and redesigned starting with a custom desmodromic valve train along with the cam drive, flywheel and engine starting system.
For this project, Exact Engineering provided the following services:
- Design of completely new cylinder head with novel metal seating poppet valves
- Design of novel desmodromic cam train including cams, rockers, camshaft, cam chain and cam block
- Cam train dynamic loads and life analysis
- Custom engine vibration isolators
- ASME certified pressure vessel for containment of heat engine
- Design of magnetic drive coupling with splined drive shaft feedthru and installation tooling
- Generator drive train design
- Globe valve actuator with position sensor for speed control and emergency shutdown
- Electrical hermetic feedthrus/li>
- High pressure (725 psi) high temperature (325 F) plumbing
- Thermally isolated and hermetic high pressure fluid feethru
- Design and analysis of system space frame to house and support all mechanical components and generator (3500lbs total).
- Fabrication, assembly and testing of heat engine and integration into vessel
- Assembly of magnetic coupling and integration into vessel
- General system assembly and testing
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Custom Workholding Tooling
Our client was awarded a production machining contract to turn a close tolerance shoulder on a small titanium elbow. They were having issues holding the part securely and repeatedly during machining. We designed and fabricated full hard custom jaws to fit on an existing tooling.
The part being very small and with little grip area posed a unique work holding problem that was further complicated by the parts material titanium 6-Al-4V which requires its own special machining processed for high production quantities
For this project, Exact Engineering provided the following services:
- Custom lathe chuck jaw design
- Structural analysis of jaws to ensure long life
- Detail part and assembly drawings
- Part fabrication, heat treat and post heat treat machining
- Assembly and delivery of custom lathe chuck workholding tool
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UAV Stabilized IR Surveillance Camera
We worked very closely with our client to review requirements and then develop a design to meet the requirements. For this endeavor, Exact Engineering provided the following services:
Structural Analysis
- Epoxy bond joint strength and athermalization
- Metering structure FE analysis and athermalization
- Primary mirror design and FEA optimization for low weight and low surface figure distortion
- Dynamic FE analysis for operating environments
- Thermal stress analysis for environmental conditions
Optomechanical design
- Large diameter thru-hole azimuth motor with custom bearings and housings
- Gimbaled primary mirror with high bandwidth scanning axis
- Composite graphite shell metering structure
- Light-weighted metal primary mirror
- Kinematic demountable mirror interface
- Flexured zero-motion interfaces for navigation components
- Light-weighted metal metering structure
- Silicon dome window mount to frame
- Materials engineering for selection of metals, epoxies and plastics
- Production of manufacturing drawings
Alignment and Assembly
- Development of alignment strategies and methodologies
- Design and all component alignment stations
- Alignment and nulling fixtures for mechanical alignments to 1 arc-sec
- Production of manufacturing drawings
- All tooling and component fabrication
- Assembly of alignment and assembly stations
- Training for use of alignment and assembly stations
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Brewster Angle Microscope
For this project, our client built a proof of concept model using off the shelf optomechanical and optical components. We worked very closely with our client to develop system requirements to ensure the microscope performed as the client desired.
This project entailed:
- Mechanical design of rotating optical bench mechanism, including actuators and position locking system
- Optical design of the telecentric imaging system.
- Optomechanical design of telecentric lens mount.
- Optomechanical design of a 1 micron resolution traveling retro-reflector system
- Detail manufacturing drawings and component fabrication
- Integration, assembly and test of components
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Handheld OEM Camera
Our client built a proof of concept model using off the shelf optomechanical and optical components. We worked very closely with them to develop system requirements to ensure the camera performed as required while meeting their cost targets.
The system required all optical and imaging components be aligned to high accuracies and to maintain alignment over thermal, vibrational and shock environments. In addition to these performance requirements, the camera was to be produced in high volumes for low cost. The client provided a ZEMAX optical model consisting of numerous “free space” optical components from which we initiated the design.
Exact Engineering provided the following services:
Optomechanical design
- Optical metering structure
- Bonded optic mounts
- Integrated optical alignment features
- Shutter mechanism for calibration
- Materials engineering for selection of metals, epoxies and plastics
Structural and Dynamic Analysis
- Epoxy bond joint sizing
- Metering structure athermalization
- Dynamic analysis for operating environments
- Thermal stress for operating environments
- Shock analysis for operation and shipping
Alignment and Assembly
- Development of alignment strategies and methodologies
- Design of eight alignment and assembly stations including:
- Mirror bonding stations
- Multi-axis optical alignment and bonding stations
- Microscope measuring and alignment station
Alignment and Assembly
- Design for manufacturability
- Production of manufacturing drawings
- Tooling and component fabrication
- Assembly of alignment and assembly stations
- Training for use of alignment and assembly stations
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Ballasted Solar Panel Array Mounting System
Solar panel arrays are well suited for placing on flat roofs of large buildings and the mounting of these panels can be performed a number of ways, roof penetrating and ballasted. Roof penetrating mounting systems are not desirable due to the high labor costs and voiding the manufacturer’s warranty. Ballasted mounting systems are held on the roof using weights, are simple to install and do not void the roof warranty.
Working very closely with our client, we captured the functional design elements from the proof of concept model and developed a number of designs that drastically reduce manufacturing and installation costs. Low cost and ease of installation were paramount, yet the most critical design requirement is that the solar array remain on the roof in winds up to 120mph.
For this endeavor, Exact Engineering provided the following services:
- Design of unique solar panel mounting systems
- Design for manufacturability
- Optimization for ease of installation
- Materials and plating engineering and selection
- Prototype manufacturing and assembly
- CFD analysis for design optimization
- Structural analysis
- Wind load analysis using ASCE 07 code
- Wind tunnel testing supervision
- Static load testing
- Production of manufacturing drawings
Six Axis Linear Stage Alignment Station
Our client built a proof of concept model using off the shelf optomechanical components however were not satisfied with the performance of the tool. They were having issues repeatably gripping the component being aligned as well as tool stability and low resolution adjustment. We worked very closely with them to develop a set of requirements to ensure we could provide a design that meets their needs.
We chose to minimize the use custom machined parts to keep costs and lead times low. Only where necessary did we design unique parts and most of these are for the kinematic end effectors. Thus the station is comprised of precision linear stages and with a custom end effector and mounts for adaptation of 1um differential micrometers. The component being aligned is gripped in the kinematic jaws of the end effector. The kinematic interface to the component ensures gripping repeatability and stability. The end effector arms are on flex pivots and one arm has compliance machined-in to prevent overclamping of the component.
For this project, Exact Engineering provided the following services:
- Optomechanical Design
- Onsite lab inspection of existing system
- Design of alignment station
- Detail part and assembly drawings
- Part fabrication
- Assembly and delivery of three stations
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