Company Overview:
Trust Automation, based in San Luis Obispo, California, is a systems-engineering firm specializing in high-performance motion control, motor drive, and power management systems for defense, industrial automation, semiconductor, and commercial applications. The company’s emerging product line includes counter–small, unmanned aircraft systems (C-sUAS) and cybersecurity-enabled motion platforms.
Project Overview:
As a Manufacturing Engineering Intern, I designed and fabricated custom tooling and mobile workstations to support Trust’s c-sUAS production line. My primary project involved creating a mobile tooling station for one of Trust’s largest C-sUAS systems, RD-SUADs. While certain project details are protected under NDA, the workstation’s purpose was to securely support and power multiple software and hardware components during configuration and testing.
Project Requirements:
- Support up to four units of equipment, each weighing 40–50
- Maintain a 2' × 2' footprint for facility space constraints
- Ensure ergonomic loading and unloading of heavy units
- Enable easy mobility for transport between testing areas
- Provide power distribution to each individual unit
- Meet a design safety factor of 3, ensuring each rack can support triple its rated loading
Deliverables and Results:
Using SolidWorks, I produced detailed CAD models, engineering drawings, and a complete bill of materials (BOM) for procurement. I also developed assembly work instructions to standardize fabrication and ensure repeatability. The resulting workstation design met all structural, functional, and ergonomic requirements and was approved for implementation on the production floor.
Structural Analysis
To ensure structural integrity, I performed load and deflection analyses on the workstation frame using SolidWorks FEA Simulation. The structure was designed with a safety factor of three, accounting for static loads from the 50 lb. units and operator handling. Aluminum 6061-T6 tubing was selected for its high stiffness-to-weight ratio, corrosion resistance, and manufacturability. The analysis revealed that the system operated well within the safety factor, even with loads exceeding 50lb. I coupled this analysis with the weight rating of the off-the-shelf clamp joints, which were also rated for loads well above 50 lbs given a distance of 3' between each joint.
Fabrication
For the initial prototype, all aluminum components were cut on a bandsaw and tapped using a drill press, while the shelving panels were laser-cut for accuracy. To reduce fabrication time, all joints and casters were sourced off the shelf. In the final design, per my specifications, the frame would be MIG-welded at the joints to enhance structural strength and overall stability.
Ergonomic Considerations
Ergonomics and mobility were key design priorities. I incorporated lockable swivel casters for stable movement between testing stations and a waist-level mounting height to minimize operator strain during loading and unloading. The rack structure features integrated cable routing for power and data management and adjustable mounting slots to accommodate future equipment revisions. These considerations enhanced both usability and long-term flexibility of the workstation.
Outcome and Impact
The final design successfully met all load, mobility, and safety requirements. Following fabrication and evaluation, the workstation was adopted for use in the C-sUAS assembly line, streamlining the equipment setup and testing process. The project reduced configuration time by approximately 25% and improved operator safety by eliminating manual lifting hazards. The success of the tooling station led to its approval as a standardized platform for future product configurations and contributed to my invitation to return as a Co-op engineer.