Kyle FitzGerald

Kyle FitzGeraldKyle FitzGeraldKyle FitzGerald
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    • Home
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Kyle FitzGerald

Kyle FitzGeraldKyle FitzGeraldKyle FitzGerald
  • Home
  • Resume
  • Work Experience
  • Projects
  • Personal
  • Contact Me

PROJECTS

Panther Robotics

Prosthetics Research

Panther Robotics

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Shaker Table

Prosthetics Research

Panther Robotics

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Prosthetics Research

Prosthetics Research

Prosthetics Research

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3D Printing

3D Printing

Prosthetics Research

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EDC Tray

3D Printing

EDC Tray

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Connect

3D Printing

EDC Tray

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FIRST Robotics Team

Started Geneva First Robotics Team

    Panther Robotics

    Founder and President

    In 2016, I started a team with a $20k yearly budget.  In addition to being president, I also was the Build Team Lead which consisted of leading the design of the robot,  supervising CAD design, and manufacturing process. I also was the Lead Driver, and our team successfully performed and advanced to World Championships twice in the first 2 years

    2018 - 2nd year challenge

    "Power Up" Challenge

    For our second year robot we constructed a robot with a 6 motor drivetrain. We took a risk using new brushless motors that were introduced that year to obtain better performance. The robot was designed to pick up crates and place them onto a scale. To accomplish this we designed a compliant wheel intake attached to a linear elevator. Throughout the design process our key focus was simplicity to reduce the risk of failure during competition.

    SHAKER TABLE PROJECT

    The Process

    For my cornerstone of engineering class my team and I were tasked with building a museum exhibit for the Boston Museum of Science that taught children about sustainability. My team chose to build an exhibit demonstrating the sustainable design of buildings to mitigate damage due to earthquakes. 


    Image Above - Assembling 3D Printed Drive Wheel

    I was responsible for prototyping and designing the shaker table. Starting with a functional cardboard prototype I applied my knowledge from building 3D printers to design a gantry on bearing blocks attached to linear rails.


    Image Above - Wiring and Mounting Limit Switches to Block Board

    The exhibit consisted of 8 blocks, each with different earthquake mitigation devices. Users would pick 3 blocks and stack them on top of the shaker table, the blocks magnetically attached to each other. The shaker table would begin moving till the building fell over which was recorded by an ultrasonic sensor. Based on how long the building survived and how expensive the block chosen, a sustainability score was produced.


    Image Above - Exhibit at Museum of Science

    Shaker Table Video Demo

    End Result - Our project was presented at the Boston Museum of Science and was enjoyed by dozens of children, while also teaching them about sustainable design.


    Check out this video showing the shaker table in

    live-action!

    Clarkson University Honors Research

    Prosthetic Thumb Function

    Prosthetic Thumb Function

    Prosthetic Thumb Function

    In the summer before my senior year of high school I participated in a 5 week research program at Clarkson University as part of the Honors Program. The project I was assigned to was designing a 3D printed prosthetic thumb for a pediatric amputee. The thumb had to be completely 3D printed and non electronic so it could be inexpensively sized as the child grew.

    Ratchet Design

    Prosthetic Thumb Function

    Prosthetic Thumb Function

    I was responsible for designing the ratcheting 3D printed thumb joint that allowed the thumb to be posed in a variety of angles. Previous designs were CNC machined from steel making them heavy and expensive. I invented a ratchet that was completely 3D printed utilizing gear teeth on the outside and 3 internal pawls on the inside. 

    Ratchet Prototype

    Prosthetic Thumb Function

    Ratchet Prototype

    Early prototypes utilized compliant pawls however these did not last long. I choose to use small springs to tension the pawls. The interior pawls were also printed out of PLA plastic and then annealed to increase their strength.

    Passion for 3D Printing

    3D Printed Ratchet

      3D Printing

      I always had an interest in emerging manufacturing technologies. At the age of 13, as 3D printing became more accessible, I purchased my own so I could learn the ins and outs of the technology. 


      My 3D printer has gone with me everywhere I’ve gone!  It has assisted in rapid prototyping, numerous research projects, developing components for various clubs, and my personal projects. This includes printing parts for my robotics team, Clarkson University research, and Formula SAE.


      I have since accumulated 3 printers all of which I have majorly modified. I have replaced all the stepper drivers, extruders, bearings and other components on my printers to get the best quality prints. I love tinkering with my printers and have built a workshop in my basement fitted out with all the equipment to do so.

      EDC TRAY - Iterative Prototyping

      EDC Tray CAD Design


      For my Iterative Product Prototyping class I was tasked with building a sustainable packaging that had a second use after the item was unpackaged. I designed a watch box that once opened folded out into a tray to organize your pocket items at the end of the day. 

      EDC Tray Prototype


      The box was constructed out of laser cut wood with a layer of EVA foam in the middle. The foam not only acted as cushioning for your items, but also as the hinge mechanism for the box.

      Connect With ME


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