At the end of my freshman year at Phillips Exeter Academy, the head of the Physics Department heard of my design and manufacturing work through the PEA Design Lab leader.

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The department head then approached me, asking if I could re-create a certain laser pen clamp used in the physics classrooms. I worked with her to identify an equipment requirement including specifications for the given laser clamp holder jig. That specific part was on short supply, and it was costly to replace and implement with traditional parts.

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Instead of purchasing the costly parts, I reverse engineered the existing part using scanning and design techniques, and then assembled the final model in CAD software. Next, I procured the hardware necessary to supplement the additively manufactured holder component. From the CAD model created, I additively manufactured the primary holder component using in-house machines, and arrived at the final version after several rounds of iteration. Then, I assembled the screws, inserts, hardware and the additively manufactured primary components to produce the final working parts. Finally, I shipped the final working parts back to school, and the Physics Department laboratory head implemented the newly created parts into the lab.

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Overall, the project was a win-win scenario for both parties, and by fabrication the parts through this alternate process, the lab head saved the department 90% of their budget allotment for replacing those parts. At the time of my graduation 4 years later, the parts were still in regular use in the physics classrooms.