Time-of-Flight Imaging Module Housings

Designed and fabricated a 3D-printed Time-of-Flight (TOF) camera housing and alignment fixture to ensure precise optical alignment between the camera lens and PCB-mounted components. The design prioritized manufacturability, repeatable alignment, and compatibility with existing hardware.

Overview:
-Designed a new camera mount and alignment fixture to accommodate PCB geometry and optical components
-Enabled precise, repeatable alignment between the TOF camera lens and laser emitter subassembly
-Optimized geometry for FDM printing with minimal support material
-Coordinated printing, tapping, and reuse of legacy camera mount designs

Design & Engineering Approach:
-Modeled the camera mount fixture as a SolidWorks assembly to ensure correct alignment and fit
-Incorporated embedded nuts to improve assembly strength and repeatability
-Used two of the four mounting holes as precision alignment pin locations
-Designed around PCB constraints and optical component stack-up to control alignment tolerances

Challenges & Technical Considerations:
-Maintaining tight alignment tolerances using FDM-printed components
-Balancing printability with mechanical precision and optical requirements
-Ensuring compatibility with existing camera mounts and test setups

Skills Learned / Reinforced:
-FDM 3D printing and slicer optimization
-Use of embedded hardware in printed parts, including CAD planning and G-code edits
-Tolerance control for precision alignment features
-SolidWorks assembly modeling for opto-mechanical systems