Rotisserie Assembly Fixture
Developed to streamline the assembly of mechanical assemblies, this fixture enables a single operator to complete builds that require access to both sides of the workpiece.
Led the end-to-end design and assembly of this tool, developing two prototypes to evaluate frame geometry, braking performance, and clamping functionality — with a focus on structural stability and operator usability. Prototypes were built from recycled extruded aluminum, sheet metal, and plastic bar stock using FDM 3D printing, waterjet cutting, and CNC machining.
Key features of the deployed design include:
Soft plastic clamping mechanisms to protect cosmetic surfaces
Rigid extruded aluminum frame to reduce vibrations during transport and use
Locking brake system for secure workpiece orientation
Hydraulic height adjustment for single-operator ergonomics
Custom bracketry to integrate off-the-shelf components
Prototypes for braking system, frame structure, and rotating mechanism is shown in the next section.
Prototyping Process
Constructed from circular and square extruded aluminum.
Concept for rotating mechanism and brakes constructed from water jet cut steel sheets and 3D printed components.
Replaced 3D printed brake components with large steel brake plates to be more durable and added a toggle clamp to lock into various rotation angles.
Custom bearings made from Acetal plastic designed and CNC machined to enable rotation of the workpiece.