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Manual Inspection Light Systems
Project Type
Mechanical Design & Manufacturing
Client
• Ultium Cells – UC2 Factory (Oct–Dec 2024, 16 units)
• Ultium Cells – UC1 Factory (Jun–Sep 2025, 40 units)
Timeline
October 2024 – September 2025 (Two Phase Deployment)
Status
Completed; 56 units deployed and operational across two factories.
Roles and Responsibilities
1. Independently conceptualized and developed the manual lighting system to address visibility issues during electrode coating inspection.
2. Selected off-the-shelf position control jig and designed a custom stud-and-nut adjustment mechanism for flexible, secure light positioning.
3. Modified commercial 7000-lumen torch lights for factory use and collaborated with the Electrical team for power supply and heat management integration.
4. Designed, 3D printed and iteratively tested a ventilated enclosure for housing the light, optimized for durability and operator safety.
5. Personally manufactured, assembled, and tested all 56 units, ensuring quality and functional consistency.
6. Installed each system directly on the coater lines at UC1 and UC2 factories, verifying operational fit and alignment with inspection zones.
7. Created internal documentation to support ongoing use and maintenance by factory personnel.
Technologies Used
1. Design: PTC Creo
2. Manufacturing: 3D Printing (FDM)
3. Materials: ABS (Thermoplastic)
4. Testing: 24-hour continuous operation test (assembled system powered on for thermal and durability validation).
Key Highlights
- Led the end-to-end development of a scalable lighting solution used for electrode coating inspection across two manufacturing facilities.
- Successfully delivered 56 fully assembled units, designed for durability, ease of use, and low-cost production.
- Designed a custom ventilated housing for a high lumen torch light, optimized for safety and continuous operation.
- Integrated off-the-shelf jigs with custom locking hardware to enable flexible and precise light positioning.
- Collaborated with the electrical team to ensure safe power supply integration and effective heat management.
- Directly installed all systems onto coater lines, supporting inspection accuracy and reducing operator fatigue.
- Contributed to approximately $40,000 in revenue through design, fabrication, and deployment of all units across two Ultium Cells factories.
Developed a robust and ergonomic manual lighting system to improve visual inspection accuracy during electrode surface coating quality checks on the production line. The system provided targeted, high-lumen illumination with manual on/off control and flexible positioning, enhancing operator efficiency and reducing missed defects. The solution included the integration of a high lumen torch light into a custom-designed, ventilated enclosure mounted on an off-the-shelf adjustable jig. The design was optimized for low-cost manufacturing, ease of assembly, and mass deployment across multiple factories.
