Malcolm is an entrepreneur, engineer, designer, product director, fitness model, and handyman. He is also a co-author of peer-reviewed articles published in the fields of mechanical engineering, geothermal energy, and dendrochronology (tree ring sciences). He has a mean roundhouse kick.
All articles from the author
Article
One of the challenges with rapid prototyping is making sure that everything fits together properly. If the design team isn’t careful with its high-fidelity models, parts assembly may involve the use of a hammer – and sometimes in frustration. With proper callouts, however, the secondary machining of 3D-printed and injection-molded parts gives designers a better […]
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Countersink holes and countersink compatible fasteners are used in all sorts of products and projects. From cellphones and computers to industrial equipment and cabinets, countersinking is used for machining metal stock, wood, sheet-metal, and even PCBs. Engineers and designers need to know what a countersink hole is and how it can be used (compatible fasteners […]
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A compliant mechanism is a mechanical system that uses flexible components such as springs, cables, and linkages to absorb energy, provide compliance, and reduce the overall stiffness of a system. Compliant mechanism designs use flexible members (often 3d printed) to achieve a prescribed range of motion and/or force. There are also secondary benefits to compliant […]
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I’ve been through the gauntlet of prototyping, design, and manufacturing a few times. I started out fixing other people’s designs with a hand file, and I’ve also designed involute gears for a low-precision injection mold. Thanks to this breadth of experience, I was able to create a simple cheat sheet for making quick manufacturing decisions […]
