Explosion Simulator PCBA Test Fixture Redesign

I was project manager and lead designer for the redesign of a blast simulator for a blast gauge. The test fixture is used in testing PCBA’s (Printed Circuit Board Assembly) under extreme air pressure to simulate an explosion for client BlackBox Biometrics, Inc. on a project for the US military. The redesign resulted in quicker test time and reduced risk of PCBA and pogo pin (spring-loaded electrical connector) damage using a hinged lid with gas struts, an easy-to-use PCBA insertion system with a lockout mechanism to eliminate incorrect insertion of the PCBA. This required a complete tear down, redesign and reassembly of the existing fixture. I designed the loading system, hinged lid system and pogo pin assembly micro adjustment mechanisms for CNC fabrication. I modified these components through testing and assembly using various milling and 3D printing equipment.