Engineering Portfolio

Ava Keras

Welcome to my website! I'm a Mechanical Engineering student @ University of Waterloo, currently engineering welds @ Toyota. Come see what I've been up to!

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Process Optimization & Controls CAD & Simulation Electromechanical Systems Design

Portfolio

Process Optimization & Controls

PLC Adhesive Control Stabilization 🎛️

Project

Stabilized adhesive dispensing system that had been facing control instability
14/28 defective glue bands creating critical gaps between roof & reinforcements.

Process

Developed Toyopuc PLC ladder logic integrating a Keyence laser displacement sensor to automate adhesive height inspection, enabling in-line quality validation by faulting out beads shorter than 5mm
Conducted root cause analysis to isolate failure mode (under-dispensing due to inadequate system configuration rather than bad part fit)
Increased dispense volume from 30 cc → 65 cc through pump system upgrades (installing new valves + piping rework)
Upgraded nozzle diameter (2 mm → 3 mm) and re-taught robot pathing (+2 mm standoff) to improve geometry, promote vertical build, & reduce sensitivity to pressure fluctuations

Result

Completely eliminated defects (14/28 → 0/28)
Increased process robustness through automated PLC quality checks + standardized system configuration.

Computer Vision Reconfiguration 🤖

Project

Optimized OMRON vision inspection system used to verify adhesive on door panels
High false NG rates were causing line slowdowns, manual rechecks, and increased cycle time

Process

Diagnosed false failures by reviewing image histograms, lighting variation, and thresholds for NG classification
Implemented region-of-interest masks to isolate true bead paths and ignore fixtures/background noise
Applied RGB filtering and contrast/noise tuning to improve bead segmentation under variable lighting conditions
Adjusted detection tolerances and defect logic to distinguish part variation with actual defects

Result

Reduced nuisance NG calls by 85%
Eliminated most manual visual rechecks leading to 5 sec cycle time decrease
Recovered lost throughput by reducing vision scan delays and line holds

CAD & Simulation

Mirror mount neck optimization 🪞

Project

Hybrid mirror mount consisting of 6061 - T6 aluminum tube and PLA mount with a structural neck

Process

Built FEA model with realistic hand-grip fixture & distributed load of mirror weight to simulate actual use
Applied local mesh refinement at neck fillet to capture peak stress without over-meshing the full model
Performed mesh convergence study to ensure accurate stress readings through iteration of decreasing mesh sizes
Compared multiple neck geometries under identical conditions
Toleranced 3D-printed insert with .5mm offset to achieve reliable slip fit

Result

Decreased maximum stress by 93% upon selection of optimal design (21.62 → 1.390MPa)
Achieved first-pass functional slip fit between printed mount & aluminum tube

Door Install Alignment Jig 🧩

Project

Custom inspection fixture for verification of door alignment
Designed for ergonomic mounting & rapid installation onto existing metrology tools

Process

Produced detailed GD&T drawing with datums, positional tolerances, and profile controls to ensure part-to-tool alignment
Dimensioned critical interfaces to control probe location relative to door datum surfaces
Fabricated via FDM 3D printing
Verified stable seating & consistent measurement contact

Result

Enabled repeatable door alignment measurements with fixed probe geometry
Reduced setup time by 5 sec by eliminating possible positioning errors
Produced low-cost fixture compatible with existing micrometer tooling

Structural Analysis Framework 🏗️

Project

Automated structural analysis framework for rapid prototyping and design validation
Developed to streamline FEA workflows and reduce manual modeling time

Process

Built Python scripting interface with SolidWorks API for parametric model generation
Implemented automated mesh generation and boundary condition application
Created post-processing scripts for stress/strain visualization and report generation
Integrated with ANSYS for advanced nonlinear analysis capabilities

Result

Reduced analysis setup time by 75% through automated workflows
Enabled rapid design iteration cycles for complex assemblies
Improved analysis consistency and reduced human error in FEA modeling

Electromechanical Systems Design

Piano playing robot by colour 🎨

Project

Lego EV3 system that translates customizable colour sequences into piano key presses with colour sensor & RobotC
A need exists for individuals to create music without dexterity or knowing how to play an instrument.

Process

Developed four-finger key actuation system with two fingers per motor to minimize motor count under EV3 I/O constraints
Designed 3D-printed gear + belt conveyor with modular tile hooks for easy sequence reconfiguration
Implemented laser-cut acrylic/plywood mounts for subsystem alignment, wire routing, and motor concealment
Programmed C++ functions for colour-to-note mapping, tempo control, and arrays for automated sheet music generation.

Result

Achieved 95% note interpretation + execution accuracy
Executed multi-cycle operation without motor stall or program failure
Fully functional prototype that is easy to use and under $60 budget constraint
Next steps: 1 actuator per key for simultaneous presses, light mount for more accurate colour scanning

Colour cruiser boat toy ⛵

Project

Locomotive boat that uses DC & servo motors for propulsion and rudder steering apparatus
Dual servo-operated doors that dispense bath dye into water

Process

Integrated DC motor + pulley drivetrain to keep motor above waterline while submerging propeller
Designed 3D-printed rudder with rounded hinge linkage for optimized hydrodynamic performance
Arduino-controlled three-servo architecture for rudder oscillation + dual-door dispense chamber
Managed mass distribution and component elevation to maintain buoyancy and prevent submersion

Result

Stable autonomous propulsion at 5 cm/s with consistent thrust
Reliable ±45° rudder steering producing non-linear pathing
Functionally isolated systems that execute core functions without brownout.

Skills

Technical skills

CAD/Sim

SolidWorks
NX
GD&T (ASME Y14.5)
AutoCAD
FEA (Static/stress)
Simulink

Controls & Automation

PLC (Toyopuc)
Machine vision (OMRON / Keyence)
Kawasaki/Nachi robotics

Manufacturing

3D printing (FDM)
DFM/DFA
Waterjet
Laser cutting
Machine shop

Programming

Python
MATLAB
C++
Arduino
RobotC

Contact

What are you waiting for?

linkedin.com/in/ava-keras

akeras@uwaterloo.ca