Battery Potting Tooling

Redesigned a potting jig concept using silicone and 3D-printed flexible components, demonstrating 50%+ reduction in cleanup effort and improved demolding ergonomics during evaluation

What I did

• Redesigned the tooling from foam-based jigs to a silicone-based approach with 3D-printed flexible components
• Improved features to simplify demolding and reduce risk of damage during removal
• Iterated design based on operator feedback to reduce cleanup effort
• Created CAD models and documentation for consistent use and handoff
• Built and evaluated prototypes to confirm workflow and performance

Validation / Evaluation

• Evaluated repeatability and workflow consistency across multiple runs
• Verified improved demolding and cleanup workflow
• Documented results and recommended implementation approach

Results

• Demonstrated more than 50%+ reduction in mold cleanup effort
• Reduced mold remake frequency (evaluation-supported improvement)
• Improved ergonomics and reduced handling variability

Tools: Fusion 360, 3D printing (flexible parts), prototype build followed with iterations, documentation

Note – This project is presented in a sanitized format to protect proprietary information.