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Navigated Ultrasound Fixtures

 

The first portion of this internship was the Navigated Ultrasound project, which uses a position tracking system in combination with ultrasound equipment to create 3D images of internal features in the patient’s body.  My responsibility was to design a series of connectors to allow existing ultrasound equipment to be used for these experiments.

Due to the remote nature of this internship, the first task was to reconstruct the ultrasound equipment in Autodesk Fusion 360, using photos provided by my supervisor. Next, I designed a single piece bracket which would hold the position sensors securely, but allow for easy removal. I used this bracket and the reconstructed models to create fixtures for the ultrasound probe and catheter. I designed these fixtures to be 3D printed as one solid piece, and they take advantage of the material’s elasticity for attachment and detachment.

The most challenging aspect of this project was recreating objects with nothing but reference photos. These objects had a great variety of fine surface details, and the brackets required a tight fit in order to function properly.

3D Printed Spring-Damper Platform

As the Navigated Ultrasound project was progressing faster than expected, I was given a second project for the summer: design a spring-damper platform which can be 3D printed and assembled by students. These platforms would be used in conjunction with an accelerometer-equipped smartphone to collect vibration data for a  remote lab course.

After several iterations, the basic layout of the platform was optimized. Store-bought seals were used for the piston rod and endcap, and the system was designed to accept several different strengths of springs. However, these early models used 3D printed threads, and it was found that not all systems could recreate these accurately. This was addressed by moving to a flanged connection, secured with bolts. The final iteration, as seen in the above pictures, is now being used by Penn State students in the ME397 course.

This project was challenging because of the short time frame. In a little less than 2 months, the design needed to be finished and ready to produce in large numbers (at least 40 sets of parts by the beginning of the semester). We ran into several issues which required immediate redesigns, but it was very satisfying to see the finished product assembled and ready to be put to use.