My goal in life was to create an industry from one of my ideas.
Developed 57 turn key business software systems for 28 customers; six over 60 thousand lines of code.
The largest was a hard goods and feed stock distribution system over 200 thousand lines of code that was used to distribute 7,000 products.
Most complex was cost modeling manufacturing system that reduced the error of projected verses actual cost by 60%. This business funded a
lot of my work.
Seven new gears and transmission concepts; patents issued on first 2 out of 3. Developed software to engineer and output
4-axis gcode to machine the conic gear and transmission parts. The goal was to changed speeds under load without interruption as shown in this
short VCT video .
US and Taiwan patents, EPO and PCT patents issued. These gears and speed changing
channels had involute profile gear teeth that meshed with a standard gear. The conic gear could not be made with current
gear manufacturing processes. The conic gear needed $millions to develop predictable engineering tools before any product
could be made. The operational speeds of the transmission were limited by having to change speeds in one rotation. Worked
on the first 5 concepts until I had to move on.
Invented new genre in total surface contact threads mathematically, high surface contact with fabrication tolerances.
There are four, patents issued on the conic, wave and concentric threads; pending on key thread. CIP and more pending.
Most of the work went into wave thread culminating in the Gemini project. This was a destructive test comparison of wave
and standard UNC threaded studs with video. The wave thread could evenly distribute stress making up to 25% stronger.
Click here to see a video of those tests .
Was developing a stronger pipe thread connection using the wave thread. The effort was to reduce the load on the tapered
ends and increased in the middle. I created the software used to make these then tested the design using FEA.
Z engineering was an effort to 3D print seals on my threads that also works on standard pipe threads. See the picture of
the first test holding 30 psi of air for 24 hours. It is a pipe threaded 3D printed cap hand tightened on the end of a pressure gauge.
My software is designed to produce parts at any desired resolution. The effect is very large files. I was creating the
CAT process., a data compression delivery system for selling nuts, bolts and studs online using Dataforged.com.
The plan was to then move into plastic gas/fluid connections with a choice of my threads or pipe threads; and add the Z seal.
While doing this I began to realized that this work was going to be a difficult business to profit from.
One of the reasons I was turned down for a NH state grant was that this work was to easy to steal.
So, I move into the key thread with the goal of creating a hard product with a bigger impact. The delivery system
for proof of concept is operational. Fine tuning a brick involves Finite Element Analysis for different materials and
destructive testing. This is were the engineering expertise is needed.
The keyed brick product development has key thread design, key sets placement; keyed brick connections and keyed brick
structures such as straight, curved, and domed walls. Each of these are separate processes that need design feedback.
At this point, these structures become the input components to existing engineering software. Then a building can be tested
on how it resists the vacuum of tornado and hurricane winds; earthquakes and the pressure of floods and avalanches.
Make a material change to the bricks and recalculate.