Collaborating within a structured team environment, I translated initial concepts into a functional, manufacturable assembly through the following development lifecycle: 

• Concept Evaluation: Reviewed and iterated on initial brainstorming sketches alongside the team lead to establish baseline requirements.

• CAD Modeling: Utilized SolidWorks to model the main cylindrical chassis, establishing critical spatial constraints and mounting interfaces.

• Mechanism Design: Evaluated multiple deployment methods, ultimately selecting a robust 3-belt conveyor configuration. Integrated commercial off-the-shelf (COTS) design elements, adapting snap-fit modular concepts for the conveyor rollers.

• Component Integration: Designed dedicated internal partitioning around the base plate to securely isolate and protect electronic components.

• Kinematic Optimization: Engineered a specialized conveyor ring assembly that mechanically links and drives all three belts simultaneously using a single servo, minimizing weight and system complexity.

• Constraint Management: Modeled custom payload holders to securely retain the flares under dynamic flight loads prior to deployment.

• Additive Manufacturing: Fabricated structural components on Bambu 3D printers, utilizing PETG for high-stress structural areas and PLA for rapid prototyping and low-load enclosures.

• Material Sourcing & Fabrication: Sourced custom rubber strip stock to manufacture bespoke conveyor belts, and procured precision hardware, fasteners, and actuation components from McMaster-Carr.

• Mechanism Optimization & Pivot: 

  • Evaluated the initial single-servo, 3-belt conveyor ring connector using a standalone servo tester.

  • Iterated through 3 ring design variations to resolve mechanical binding issues; ultimately determined the complex ring synchronization was a failure point.

  • Successfully pivoted to an independent, dual-servo and 2-belt system, significantly increasing mechanical reliability while streamlining assembly.

• Volumetric & Weight Efficiency: 

  • Downsized payload capacity from 3 to 2 units to optimize structural space constraints and reduce overall system volume.

  • Integrated hexagonal pocketing and truss geometries throughout the chassis to minimize component mass without sacrificing structural rigidity.

• Rigid & Reliable Component Mounting:

  • Designed custom servo clamps to securely anchor the actuators and eliminate mechanical play under dynamic loading.

  • Simplified payload holder geometry to improve reliability, securing the holders directly to the conveyor belts.

• Aircraft Interface & Retrieval Integration:

  • Incorporated dedicated guide holes for high-tensile fishing line to interface directly with the aircraft's winch system.

  • Integrated external structural pass-throughs for alignment netting, ensuring smooth, snag-free guidance as the basket is re-docked into the fuselage.