PORTFOLIO Ken Orr –Design Engineer/Owner

1. PORTFOLIOKen Orr –Design Engineer/Owner

2. Services • 3D design engineering utilizing Pro/ENGINEER • Complex Surfacing and Assemblies • Sheetmetal • Mechanica, static only (structure & thermal) • Drawings (to ASME-Y14.5M standards) • Packaging studies • Simple fixture design • Plastic part design (an Orrbit Design specialty) • Project Management • Prototyping • SLA or Objet • Urethane Castings • CNC machining • Finish Work (hand crafting, painting, etc.)

3. Example – Patio Umbrella***Patent Pending*** • 110V Powered Patio Umbrella • Design included electrical housings, crank mechanism, and assembly. • Prototypes supplied using SLA/Objet masters to generate silicone molds for multiple cast parts.

4. Example – Cordless Phone • Cordless Phone and charging base • Class-A complex surfacing • Generation of Front Cover, Rear Cover, Battery Cover, Display Window, Keypad, Belt Clip for Injection molding • Integration of electronics with display lens, earpiece connector, and battery charging contacts

5. Example – Lawn Edging • Wheat & Rock simulated Lawn Edging • Integrated intricate designs for injection molding utilizing scan data with solid modeling • SLA prototypes generated, and painted with production intent colors

6. Example –Remote • Spa Remote Control • Class A surface • Front Cover, Rear Cover, Battery Cover, Tactile Keypad, Display Lens, Rubber Key, Wall Plate • Integrated Electronics includes display, thin tactile keypad top keep water proof • Prototypes supplied using SLA/Objet masters to generate silicone molds for multiple cast parts in a urethane material. Keypads were prototyped by keypad manutacturer

7. Example – Gateway • Gateway for Schlage lock system • Class A surface for black injection molded parts • Front Cover, Rear Cover, Battery Cover, Keypad w/integrated light pipes • Integrated Electronics included PCB w/vertical mount switches, RJ45 jack & battery w/light pipe out front • Prototypes supplied using SLA/Objet masters to generate silicone molds for multiple cast parts in a urethane material.

8. Example – Caulk Gun • Caulk Gun for 5.5oz tubes • Class A surface • Right & Left Covers, Tray with motorized screw feed mechanism (Acme thd) with release trigger & gear system to drive feed mechanism • Integrated Electronics & battery pack • Prototypes supplied using SLA/Objet masters to generate silicone molds for multiple cast parts in colored urethane Actual prototype

9. Example – Tubs • Bath & Spa tubs designed for Vac Forming from high gloss sheet stock • Class A surfacing • Continuity of rounds was crucial to this process • Non skid on floor w/jet & drain locations

10. Example – Bench • KLM Bench, commercial seating (8 person shown) • Legs designed for aluminum casting w/high gloss polished finish • Designed to support up to 450lbs per seat

11. Example – Water Cannon • Toy Water Gun • Class A surfacing • Hand run crank to pump water • Base designed to adapt to a boat or dock • Nearly 45 degrees of tilt front/back and swivels full 360 degrees.

12. Example – Seat Back Sail • Sail for office furniture side chair • Class A surfacing • Each intersection had to be cut away and a surface blend created to meet designers requirements

13. Example – Swim Device • Wrist, Ankle & Head devices to monitor swimmers • Units are required to be water proof to IP68 & air tight to 0atm in a cargo hold of a plane with no change in the unit when held in your had at ground level. • Top cover is an inset molded part with a 60 durometerSantoprene material to allow activation of 2 switches.

14. Example – Medical Device • Medical device • Package electronics into small enclosure with 3 switches • Top cover is an inset molded part with a 40 durometerSantoprene material to allow activation of switches. • Back cover is formed metal stamping

15. Example – Mechanism Cover • Mechanism Covers • Develop new mechanism covers for an office furniture chair • Worked closely with Industrial Designers to capture design intent • Created skeleton model to ensure proper form between upper and lower cover

16. Example – Chair Seat Development • Chair Seat • Develop new seat for a new chair • Create structural plastic lower that mounts to cylinder mounting plate. Worked with FEA to determine best rib structure and wall thickness • Create release lever for fore/aft adjustment and a cover for the “no option” option

17. Example – Chair Back Frame • Chair Back Frame • Develop new back frame for an office furniture chair • Worked closely with Industrial Designers to develop best ProE class-a surfacing • Parts had to have mating surfaces for a sonic weld operation, this required the sharing of data between files (publishing geometry) • Because of the sharing of data between file, the best method was use of a skeleton model

18. Example – Cervical Spine Display • Cervical Spinal Display Model (C4-C6) • Develop 2ft wide cervical bone models for use in a medical expo • C4 and C5 to rock 10degrees left/right • Design of motion mechanism to fit within the main body of the bone

19. Contact • Orrbit Product Design LLC • Ken Orr • 243 129th Ave. • Holland, MI 49424 • 616.240.7200 • ken.orr@orrbitdesign.com • www.orrbitdesign.com