Alex RoweEngineering and Design Portfolio

B.E. with Concentration in Mechanical Design | 2015A.B in Environmental Studies | 2014 Thayer School of Engineering, Dartmouth College

alex.r.rowe@gmail.com(303)506-9476

Alex Rowe welding handles to mount brake levers on a diwheel. More information on this project on pages 6-7.

Welcome!

About meMy name is Alex Rowe, and I grew up in Denver, Colorado. I am an engineer, chef, and avid lover of the outdoors. My undergraduate education began by following my love of nature in the pursuit of a degree in environmental studies. This degree taught me systems thinking and to access effective leverage points when choosing a course of action. Simultaneously, I worked professionally as a chef in contexts as diverse as a remote hiking lodge in Northern New Hampshire and a French influence restaurant in Vail, Colorado. Kitchen philosophy taught me the importance of preparation, organization, efficiency, and dedication to a craft.

My desire for more scientific and hands on learning led me to a degree in mechanical engineering with a focus on machine design. In the last few years, I have grown tremendously as a mechanical designer and scientist, culminating in my senior project team being awarded the Dartmouth Society of Engineers Prize for outstanding performance in an engineering project.

I draw on my experiences as an outdoorsman, systems thinker, and practitioner of the ‘mise en place’ culinary phi-losophy in all of my engineering work. I am excited to bring my unique mix of skills to my engineering career.

Advanced Courses in EngineeringComputer Aided Mechanical Design — Advanced SolidWorks, CAD, CAM, FEA, and rapid prototyping and manufacturing techniques

Advanced Solid Mechanics — Macroscale material analysis and selection for design

Engineering Design Methodology — Capstone design project. Developed semi-prone bicycle

Statistical Methods in Engineering —Probability and statistics, DOE, hypothesis testing, regression analysis

Engineering and Climate Change — Investigation into climate science, literacy, and leverage points

Undergraduate Engineering CoursesDistributed Systems and Fields, Discrete and Probabilistic Systems, Dynamics, Machine Engineering, Science of Materials, Scientific Computing, Structural Analysis

Undergraduate Environmental Science Courses and FocusesPolar Science, Climate Change and Climate Science, Systems Thinking, Geographic Information Systems, Environmental Economics, Environmental Law

Skills and ExperienceSoftware: Solidworks (Certified Solidworks Professional), HSMWorks CAM, MATLAB, ArcGIS, Adobe Creative Suite,

MiniTab, MathCAD, Microsoft Office, Google Cloud Services

Manufacturing: Injection Molding, CNC & 3D Milling, CNC Lathe, Welding, Plasma and Laser Curring, Lean Six Sigma Green Belt (anticipated November 2015)

Other skills: Photography, Motion Capture, Cooking (2 years professional experience)

Activities: Backpacking, Mountain and Road Bicycling, Skiing, Improv Comedy

“Libby Leaner” — A novel bicycleENGS 89/90 – Engineering Design and Methodology

A physical therapist from Woodstock, Vermont approached a team of six Thayer students with an idea for a forward leaning bicycle that would be safe, powerful, and comfortable. We designed, manufactured, and tested a novel bicycle design, rider position, and rider support mechanism.

Received Dartmouth Society of Engineers Award for outstanding project performance.

Problem: Bicycle users experience discomfort and suffer injuries from the conventional bicycle’s seat, geometry, and body position.

Need: In light of advances in the fields of ergonomics and biomechanics, there is a need to find an alternative body position to the state of the art and implement it in a novel design.

Lead Responsibilities:• Testing design and analysis• Biomechanics lead• Bicycle mechanics • Print material design

Frame Design — Three prototypes constructed, CAD modeling and analysis

Middle: A rendering of the final Solidworks model of the leaner. Right: A ‘hack and slash’ proof of concept, i.e. prototype one. Left: A few of the frame designs generated in the industrial design workshop.

After choosing a body position, a proof of concept prototype was created. Then, the team did an industrial design work-shop to brainstorm frame designs, with emphasis on aesthetics and manufacturability. Following this, a second prototype was created and tested. After heavy refinement, the final prototype was developed, as can be seen above.

“Libby Leaner” — A novel bicycleENGS 89/90 – Engineering Design and Methodology

Biomechanics testing and choice of body position

During the initial design process, it was necessary to choose a rider position scientifically. The team built a highly adjustable stationary bicycle to test various rider positions. I designed a test process that used motion capture photography, rider power output that was determined via pedaling rate and bike stand resistance, and user surveys of comfort.

A test subject in four different positions on the adjustable stationary testing bicycle. Silver markers are used to track the rider via motion capture.

The motion capture photography outputs a point cloud – x, y, and z values for position rel-ative to a user defined origin – at a rate of 32 frames per second. A partner and I developed a MATLAB script that inputed this point cloud data and outputed joint angles throughout a pedal stroke relative to a relaxed standing position.

Goals: Neutral neck and back position, open hip, maximize power, maximize comfort.

Data Analysis

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Left: Left knee flexion for one subject. Several trials in gray with average in red. Right: Left hip flexion average values at five riding positions for one subject.

Body Support Mechanism — Four rounds of prototyping, user testing, expert consultationUnexpectedly, one of the largest challenges of the project was designing a comfortable support for the rider. In the first round of prototyp-ing, approximately one dozen supports were made from foam and fiberglass. This round emphasized exploring the design space by making many supports. During prototyping round two, we narrowed the decision to a foam roller or bungee style support. Round three led to refining the bungee support and creating a hammock style support. Following round three, we consulted a high end office furniture manufacture for expert advice on prototype refinement and material selection. Implementing their advice, we developed prototype round four which led directly to the

From left to right: Round 1 – Some of the foam and fiberglass prototypes developed. Round 2 – The initial bungee support. Round 3 – Refinement of the bungee support to a hammock style support. Final design – Stemming from prototype round 4, plastic webbing with directional flexibility was used to support the torso on a curved steel frame.

Diwheel — Human powered vehicleENGS 146 – Computer Aided Mechanical Design

Lead Responsibilities:• Drive wheel design and manufacturing• Differential design• Frame member cutting and welding• Bicycle component mechanics

Challenge: Create a human powered vehicle in which the rider sits between two 36” hoops that are propelled by drive wheels. Vehicle designed to compete in a four event competition that requires balance, straight driving, tight steering, and speed.

Received Class Prizes for Innovative Design and Team Spirit.

Drive wheel design — Using cogged rubber v-belts to increase drivetrain efficiency Historically, Thayer diwheels have suffered from aluminum drivewheels slipping on the steel hoops. I designed a wheel that had a rubber v-belt with an internal cog that meshed with a laser cut piece of wood. The v-belt spline was reverse engineered for the wood piece. These parts were sandwiched between plasma cut steel plates for rigidity. The result was superior traction, with no slipping in any test or competition conditions.

Left: The inside of the drive wheel. Right: FEA analysis of the stress on steel plates from bolts compressing the rubber belt. Used to determine the necessary number of fasteners.

Diwheel — Human powered vehicleENGS 146 – Computer Aided Mechanical Design

Differential design — Bevel gear differential designed for size and simplicityA figure eight portion of the competition required tight steering that necessitated a differential. My major design contribution was to press fit the gears into large flanged bearings that were then press fit into the aluminum walls. I also designed the steel supports with press fit acrylic windows.

Left: A solidworks model of the bevel gear differential. The drive shafts are protruding from two of the gears and have notches for snaprings to align bearings. Middle: The manufactured differential. Size was a driving constraint. The handheld differential easily fit between the rider and the ground. Right: The drivetrain on the frame. Shaft collars were welded to the frame so the drivetrain could easily be removed without adjusting the bearing positions.

Frame — Designed and analyzed in Solidworks, manufactured in houseThe frame design was a collaborative effort. I was the lead on cutting members and welding the frame.

Left: FEA analysis of the frame, followed by the decision to add an additional support.Above: Rendering of the final frame. Includes device used in plunger carry competition.

Injection Molded Yo-Yo ENGS 146 – Computer Aided Mechanical Design

Use Solidworks mold tools and CAM tools to design a yo-yo mold. Machine the mold using 3 axis CNC milling. Make several yo-yos with injection molding.

Left: Solidworks model of concave half of yo-yo mold. Middle: Solidworks model of convex half of yo-yo mold. Right: Machined mold for use with an injection molder.

Rhombic DodecahedronENGS 146 – Computer Aided Mechanical Design

Model an abstract shape in Solidworks, with an ornamental design. 3D print six pieces so that they fit together in a puzzle. An exercise in tolerancing and 3D sketching, when done correctly, the puzzle would easily slide apart along one axis, but would other-wise fit snuggly.

The design is a combination of a piece of my brother’s artwork and a tribute to my love for chili peppers. More about this on page 11.

Solidworks models of an individual piece, and of the complete puzzle.

Cooler EarmuffsENGS 21 – Introduction to Engineering

Faced with the problem of, “engineering a quieter society,” I worked with a team to design and build prototypes of over ear hearing protection that would not overheat, reducing misuse.

Successfully reduced steady state temperature without compro-mising noise protection by replacing traditional vinyl padding with vented silicon padding.

Model of the final design for the cooler earmuff.

Remote control machineENGS 76 – Machine Engineering

Design a machine to play a game in which various size balls were collected from the floor and deposited in a 12” high basket.

Responsibilities: Design and manufacture a pair of three stage gearboxes using limited available spur gears. Use the gearboxes in conjunction with two DC motors and roller chain to create a tank steering drive system. Machine all chassis components.

A demonstration of the machine collecting a softball, driving to the basket, lifting, and depositing in the basket.

Obstacle CourseENGS 76 Teaching Assistant

As a full time teaching assistant for machine engineering, I guide the design, modeling, and fabrication of walking machines for participation in an obstacle course. I constructed the course and assisted with the design and modeling.

A wooden obstacle course for students walking machines including a maze, teeter totter, dowel forest, and wall.

3D Printed BridgeENGS 33 – Solid Mechanics

As an introduction to solid mechanics, teams of three designed bridges that had to fit a series of size and shape constraints, were 3D printed, and tested to failure to detrmine stregth-weight ratio.

A series of bridges from the class. My bridge is the green bridge nearest the camera

Conserving the Stage — GIS WorkGEOG 59 – Environmental Applications of GIS

A representative from the World Wildlife Fund reached out for a student group to complete a project in landscape classification. I worked in a group of three to develop a procedure for dividing a landscape into similar sections based on geophysical qualities. The theory states that geophysically diverse areas can support high future biodiversity despite an uncertain climate. Study area matched areas of snow leopard sightings in High Asia, an interest of the sponsor.

Maps developed were included in internal publication at World Wildlife Fund.

Left: Final product, a map of High Asia classified into 8 land facets based on geophysical qualities.

Above: Procedure developed for geophysical landscape classification.

Below: Individual layers developed as part of procedure.

Con Todos Tacos — Friends and FoodPersonal challenge in cooking and community building

A taco con todos, is a taco with the works. Con todos tacos are tacos eaten with everyone (con todos). I be-lieve in the importance of community and the bonding power of food.

Twice a month for a year, I would prepare a completely from scratch meal for anyone and everyone who was in-terested in coming. Attendance was always between 20 and 60 guests. I made everything in house, including: tortillas, carnitas, lengua, pulled chicken, veggie fillings, dried chile salsas, salsa verde, pico de gallo, pickled onions, sopapillas, and tres leches cake.

The effect was infectious. My brother, an artist and graphic designer, made me a logo and printed it on fabric that I made into hats. A roommate fictionalized the event for his creative writing final. Long time friends would come and cook with me for hours. Every-one was invited to eat, and many people chose to help, volunteering to do everything from pressing tortillas, to frying sopapillas, to washing dishes.

The project culminated with Con Todos Tacos part-nering with TheBox, a food truck in Hanover, NH. My recipes were served for one night. That night remains the most profitable shift the food truck has ever seen.

A testament to the power of delicious tacos and strong communities.

Jarred salsa for Christmas presents, giveaways, and thank yous

Chiles are best when fire roasted in your backyard

A Con Todos hat. Fabric and logo design by Max Rowe. Sewing by Alex Rowe

Getting excited about candy striped beets.