Projects

Here is a page of both my professional and personal projects

KALVOAI

Kalvoai delivers end-to-end manufacturing technology solutions, from initial process development and sensor integration to advanced MES and cutting-edge manufacturing applications.

Assembly Assistant

Assembly Assistant is a real-time AI camera system that instantly inspects assembly quality and tracks production progress. It simultaneously monitors both quality and progression by communicating directly with your SCADA system.

Infinitum Electric

Infinitum Electric is modernizing motor technology for a sustainable future. They design and manufacture smaller, lighter, and more energy-efficient motors that use fewer resources, reduce emissions, and are built with remanufacturing in mind. Their focus is on reducing carbon emissions and maximizing energy efficiency by reinventing the age-old electric motor. You can learn more at their website: Infinitum Electric.

Rotor Assembly Machine

A fully automated assembly machine to assemble a rotor for an axial flux motor. 

  • Laser Ablation for packing oil removal 
  • Adhesive activator dispense system 
  • Primary Adhesive dispense
  • Oven Cure System 
  • Rotary Balancing 
  • Magnetizing 
  • Ignition SCADA Integration 
  • MES Integration

Semi-Automated Assembly Machine

A semi automated assembly line for axial flux motors which included both automated processes and manual processes linked together on a single piece flow conveyor. 

  • Automated screw driving
  • Bearing Press
  • Top Rotor Press 
  • Automated Sub Assembly Test Station
  • Flipping Station 
  • Final Assembly Test 
  • SCADA Integration 
  • MES Integration

JUUL Labs

Juul Labs aims to transition the world’s adult smokers away from traditional cigarettes by offering innovative vapor products. Their mission focuses on providing a satisfying alternative while combating underage use of their devices. You can explore their products and learn more about their commitment on their website: Juul Labs.

High Volume Pod Assembly

A high volume fully automated assembly system consisting of 3 primary stages, sub assembly, final assembly and packing. 

  • 20k UPH (Units Per Hour)
  • 60 Vision Inspection Systems (Omron, Keyence, Gig-E) 
  • SMT Reel Feeding Components 
  • PnP, Punching, Filling, Dispense, Laser Etch, Laser Weld, Plasma Treat, IC Encoding, Weight Check
  • SCADA Integration (Ignition) 

Electronic Device Assembly

Semi Automated assembly line to assemble the electronics devices in a clean room environment. 

  • Laser Soldering
  • Battery Assembly Machine
  • Sami-Automated Dispense 
  • Force Controlled Assembly 
  • Laser Etching
  • Final Assembly Test System

Apple

Apple (apple.com) is a multinational technology company renowned for its innovative consumer electronics, software, and online services. 1 They design, develop, and sell a wide range of products, including the iPhone, iPad, Mac, Apple Watch, and AirPods, alongside services like the App Store, Apple Music, and iCloud. With a focus on user-friendly design and a tightly integrated ecosystem, Apple has become one of the world’s most recognizable and influential technology brands.  You can explore their products and learn more on their official website: Apple. 

Fully Automated Processes

  • Battery Installation 
  • Laser Welding 
  • Ingress Testing 
  • Laser Etching
  • Adhesive 
  • OLED Display Installation
  • Camera Assembly Install
  • FaceID Assembly 

ABB

ABB Robotics (new.abb.com/products/robotics) is a leading global supplier of industrial and collaborative robots, as well as autonomous mobile robots and machine automation solutions. Their comprehensive portfolio is designed with value-creating software to help companies across various industries, from automotive to electronics and logistics, enhance their resilience, flexibility, and efficiency as they transition to the connected factory of the future.

Fully Automated Processes

  • Automotive Door Assembly 
  • Automotive Displays/Body Assembly 
  • Transmission Components
  • Consumer Makeup 
  • Food/Beverage 
  • Electronic Connector Assembly 
  • PCB Assembly 
  • Hydrogen Fuel Cell Assembly
  • Fuse Box Assembly 
  • Adhesive Dispensing 
  • Automated Optical Inspection

Safran Aerospace

Safran (safran-group.com) is a global high-technology group with a significant presence in the aerospace market, encompassing aircraft propulsion, equipment, and interiors. They design, develop, and manufacture a wide array of critical components and systems for commercial and military aircraft, including engines, landing gear, nacelles, wiring, avionics, and cabin interiors, contributing to safer, more sustainable, and more comfortable air travel.

Product Design

  • Product Design Patent: US9,984,845B2

Manufacturing Processes

  • LCP Injection Molding
  • Bimetallic Materials
  • High Current DC Device Testing
  • Soldering

Sun Hydraulics

Headquartered in Sarasota, Florida, Sun Hydraulics (part of Helios Technologies) is a leading designer and manufacturer of high-performance screw-in hydraulic cartridge valves and manifolds. 1 Since 1970, they have specialized in creating compact and powerful hydraulic control solutions that manage force, speed, and motion in a wide range of industrial and mobile equipment. 2 Their innovative cartridge valve technology is distributed globally through independent partners. 3

Automated Processes

  • Counterbalance Cartridge Valve Assembly 
  • Cartridge Valve Final Testing 
  • Grinder Machine Tending 
  • Packaging laser marking and autoloading 
  • Edge Chamfer 
  • Pneumatic Sub Assembly Test 

Personal Projects

In my personal time, I’m driven to explore emerging technologies and develop innovative tools for the manufacturing sector. Here are some projects I’ve pursued as opportunities arise.

More Coming Soon!

Process 1

Description

- Feature 1
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Have Project in Mind?

Let’s Turn your Ideas
into Reality

justinmelmarclay@gmail.com
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