Designed a precision camera calibration fixture for Instron’s testing systems, applying GD&T principles, exact constraint theory, and design for manufacturing to ensure repeatable positioning and efficient production.
Camera calibration fixture design
Design Challenges
Instron’s vision-based testing systems required a reliable method for camera calibration to ensure measurement accuracy. The fixture needed to position calibration targets precisely and repeatably while being manufacturable through standard CNC processes.
Technical Approach
I designed the fixture from the ground up, applying exact constraint theory to ensure kinematic positioning without over-constraint. Each interface point was carefully considered to provide the necessary degrees of freedom while preventing unwanted movement.
The design incorporated comprehensive GD&T callouts to communicate critical dimensions, tolerances, and datum references to manufacturing. This ensured the machined parts would meet functional requirements and assemble correctly without expensive trial-and-error.
Design for manufacturing principles guided material selection, feature accessibility for tooling, and tolerance stackup analysis to balance cost and performance.
Results
Successfully delivered a fixture design ready for CNC production with complete technical documentation. The design demonstrated advanced understanding of mechanical constraint, tolerance specification, and manufacturing processes.
Skills Applied
GD&T (Geometric Dimensioning & Tolerancing), exact constraint theory, design for manufacturing (DFM), CAD design, tolerance analysis, technical documentation