ROBERT MELVIN – INDUSTRIAL DESIGNER
A multidisciplinary problem-solver, industrial designer, and expert with analysis and strategy to meet usability and functional requirements.
Glass Aeropress
A glass Aeropress alternative using BPA-free and non-toxic materials.
Borosilicate glass cylinder.
Food grade silicone piston and seal.
Able to fill inverted on table prior to placement on cup for dispensing brewed coffee.
Quick assembly and cleaning.
Uses available compostable paper disc filters.
Maglev Array
Innovation and intellectual property development of rotary maglev arrays.
Mechanical design and implementation of a safe method for high RPM testing.
Aluminum assembly is an adjustable radial compression holder for array prototypes.
Enables 3D printed plastic prototypes to be used without fragmentation danger.
Bike Box
Flat-Pack bicycle ship and transport box.
Flat-Pack for efficient inventory, distribution, and storage.
Reusable and recyclable.
Crush zone frame for protection.
Grid-based universal fit system.
Band attached wheels and handle for ease of transport by one person.
Disaster Recovery Shelter
Design for a disaster recovery support shelter.
Shelter deploys from a 20’ long shipping container to 4x of the container floor area.
Has secure-able stair so first floor with facilities may serve as a common area for a team.
Shelter can be demounted, repacked, reused, and refurbished.
Final Product Evaluation
Product design, mechanical design, and intellectual property development for a patented product.
Connects to the trailer ball on a hitch; the only dimensionally standard part.
Uses tungsten carbide inserts to engage the trailer ball and reduce chance of slippage.
Creates a balance point to carry, remove, and install receiver hitches while avoiding dirt and grease.
Utilizes injection molded glass-filled Nylon, laser cut steel, and shear load transfer fasteners.
Patented.
Wall Panel
Wall system uses honeycomb core panels with fiberglass faces.
These honeycomb core panels are used to construct some semi-tractor trailers and are recyclable.
Panels are joined and sealed with tubular structure using wedging and clamping spring clips.
Spring clips self adjust and can progressively tighten into panel frame groove in response to movement.
Espresso Grinder
Directly relates burr rotation to grind output.
Uses weighed output of prior grind or sample grind to calculate operation for target amount.
Grinds immediately depart from burrs downward without interruption or diversion.
Complete bean and grounds path is quickly cleanable using magnetically attached removable parts.
Taper-fit inner burr shaft detaches from motor for easy cleaning.
Uses standard Mazzer burr sets.
Patented.
Sequence
Design for a disaster recovery logistics and support structure.
Shipping container carries 3x additional floor plates on roof for deployment.
Masts assist deployment, support the roof, and allow mounting of solar and communications equipment.
Wall system uses insulating honeycomb core panels.
Wall panels are joined using tubular structure using wedging and clamping spring clips.
Wall panel frames have linear elastomer seal which is compressed by spring clip force.
Datalogging Test Machine
Mechanical design and implementation of 5 kW servo, numerically controlled datalogging testing machine.
Machine designed to allow up to 2’ diameter maglev arrays to be tested.
Monolithic Z-axis pillar improves accuracy.
Torque reaction structure handles potentially damaging loads.
Optical encoder and brake on Z-axis. Brake engages upon power loss.
Driven axles have adjustable precision tapered roller bearings and ER collet based chucks both top and bottom.
Shrink Fit Axle
Mechanical design and implementation of precision axles.
Parts are prepared with and interference fit condition for shrink-fit process to create permanent and highly concentric connections without creating issues such as weld distortion.
Integration of commercially available ER collet extensions into a custom axle assembly.
Maglev Hover Engine
Innovation and intellectual property development of rotary maglev arrays.
Mechanical design and implementation of hover engines.
Shows interference fit to retain array magnets in aluminum hub against significant magnetic forces.
Design additionally retains magnets by vacuum epoxy potting process which is capped with lasercut plastic cover.
Vaccum epoxy potting process used to eliminate voids and bubbles to avoid unbalanced assemblies.
Verifying Machined Parts
Freshly machined parts are being inspected and the dovetail feature is being dimensionally verified using precision gauge pin.
Inspection with the gauge pin showed dimensional accuracy to approximately 0.0004”.
The machine shop producing these parts was operated by a tool and die maker.
Final Product Evaluation
Mechanical design and product design for interlocking and stackable blocks to make plant containers.
Has features to accept decking screws, rods, or landscape nails for secure location of blocks.
Mold strategy shown.
Blocks contain fully drafted features and ribbing to allow ease of production, positive mechanical engagement between blocks, reduction of plastic volume needed, and to reduce distortion defects.
Final Product Evaluation
Product design, mechanical design, and implementation.
Shows a unique espresso tamper design for improved ergonomic use and reduced repetitive motion injury.
Zero clearance compression fit dovetail joint handle is removable for cleaning.
Edge thickness and overall shape designed for tactile feedback for quick accuracy.
A comprehensive awareness of technology, art, and structure allow me to discover ways to move design and innovation forward so my clients receive new opportunities to create value. Strong mechanical design skills are an expression of my desire that ideas be fully translated into reality; that things work, work well, and deliver real-world results.
My background includes leading an innovative and highly productive engineering team in a technology startup, working independently in a freelance capacity, and filling many different roles. I love to learn and my education includes an MS degree in architecture, an MS degree in sustainable Systems, and a BS in horticulture. Over time, I have had many opportunities to learn amazing things from people who are skilled at what they do.
Successful innovation and IP development are strengths reflected in patents covering the range from mechanical solutions to magnetic levitation implementations.
| Patent / Publication # | Year | Subject | Note |
|---|---|---|---|
| 2019/0140562 A1 | 2019 | Maglev Rotary Array Assembly | Inventor |
| 10,173,549 | 2019 | Maglev Vehicles w Hover Engines | Named Inventor |
| 9,862,288 | 2018 | Magnetically Lifted Vehicles w Hover Engine | Named Inventor |
| 9,744,878 | 2017 | Magnetically Lifted Vehicles w Hover Engine | Named Inventor |
| 9,707,859 | 2017 | Magnetically Lifted Vehicles w Hover Engine | Named Inventor |
| 9,522,610 | 2016 | Magnetically Lifted Vehicles w Hover Engine | Named Inventor |
| 9,352,665 | 2016 | Magnetically Lifted Vehicles w Hover Engine | Named Inventor |
| 9,325,220 | 2016 | Magnetically Lifted Vehicle Propulsion and Control | Inventor |
| 9,263,974 | 2016 | Magnetic Lift Using Hover Engine | Inventor |
| 9,254,759 | 2016 | Magnetically Lifted Vehicle Propulsion and Control | Inventor |
| 9,126,487 | 2015 | Magnetic Lift Hoverboard | Inventor |
| 9,066,629 | 2015 | Numerically Controlled Espresso Grinder | Named Inventor |
| 9,050,720 | 2015 | Hitch Coupling Tool | Named Inventor |
