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Eli Lewis

Projects

AllEngineeringManufacturing & shopElectronicsDesign & craft
Skills5s-leandesign-for-productiondesign-for-repairelectronics-assemblyfacility-layoutflatness-inspectionhand-tool-woodworkinghardware-moddinghuman-centered-designinventory-systemsmetrologymicro-solderingproject-planningprototypingstakeholder-coordinationtool-makinguser-testingworkflow-design
Ely Tool shop reorganization: Final plan for the main floor, modeled to scale in SketchUp. I discussed with the lead engineer to establish large moves and location for the new CNC machine (large upper left profile). I worked out everything in between--exact orientation, storage cabinets, worktables, manual machines. Colors: green = in final position, orange = planned, not yet moved, red = remove, purple = review, brown = work surface, yellow = keep contents. Large shaded margins = space needed to service a machine; white circles = 12, 8 and 5 ft gauges for checking the new hallway widths.
2 parts

Ely Tool shop reorganization

  1. 1. Shop floor relayout without a shutdown
  2. 2. Detail room: $0 storage plan and barcode lookup prototype
facility-layout5s-leanstakeholder-coordination
Close-ups, wheelchair to switch: rubber-lined clamp, ball-joint stack, foam clamp assembly, foam pad

PressAble: an adjustable, shock-absorbing switch mount

A low-cost highly-adjustable upgrade for a school's existing gooseneck switch mounts: quick, fine adjustment from two ball joints, and a foam buffer that absorbs hits from any direction.

human-centered-designuser-testingprototyping
The finished plane

Wooden Krenov-style hand plane

Krenov-style oak smoothing plane, sole flat to ±0.001 in, built under a professional woodworker's guidance

hand-tool-woodworkingtool-makingflatness-inspection
Finished handheld: GameCube-style controls around the built-in screen

Portable Wii built by soldering to 0.1 mm traces

Micro-soldering, motherboard trimming and 3D-printed enclosure assembly, built to the open-source Ashida design

micro-solderingelectronics-assemblyhardware-modding