Lauren Zemering

Lauren Zemering

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Hardware product design

Commercializing a 3D vision scan table

Industrial design

Context

CapSen Robotics specializes in 3D vision and motion-planning software that gives robotic arms the spatial intelligence to pick and sort random, cluttered objects. To detect and manipulate these parts, the vision system first requires a complete 360-degree digital mapping of the object to train the model.

Context

CapSen Robotics specializes in 3D vision and motion-planning software that gives robotic arms the spatial intelligence to pick and sort random, cluttered objects. To detect and manipulate these parts, the vision system first requires a complete 360-degree digital mapping of the object to train the model.

Challenge

The 3D vision team relied on a rudimentary, unmarketable scanning rig, preventing CapSen from bundling a professional hardware asset with their cutting-edge 3D vision software for enterprise clients.

Challenge

The 3D vision team relied on a rudimentary, unmarketable scanning rig, preventing CapSen from bundling a professional hardware asset with their cutting-edge 3D vision software for enterprise clients.

Role

Lead product designer

Duration

4 months

Company

CapSen Robotics

Skills

User research

UX/UI

Product management

Accessibility

Design system

Tools

Autodesk Fusion 360

MakerBot

1

Scoping the project

To transition the prototype to a viable commercial asset, I established a strict framework balancing aesthetics, cost, and a low-volume production run (scale of 10s to 100s of units).

  • Constraints: Mass injection molding was financially unviable for this production scale. The architecture had to lean on affordable off-the-shelf (COTS) components and local low-volume fabrication methods optimized for rapid in-house assembly.

  • The Standard: The final unit required an industrial-grade, rugged aesthetic reflecting CapSen’s high-tech brand identity while surviving harsh warehouse environments.

1

Scoping the project

To transition the prototype to a viable commercial asset, I established a strict framework balancing aesthetics, cost, and a low-volume production run (scale of 10s to 100s of units).

  • Constraints: Mass injection molding was financially unviable for this production scale. The architecture had to lean on affordable off-the-shelf (COTS) components and local low-volume fabrication methods optimized for rapid in-house assembly.

  • The Standard: The final unit required an industrial-grade, rugged aesthetic reflecting CapSen’s high-tech brand identity while surviving harsh warehouse environments.

2

Hardware & tooling research

  • Deconstructing the Rig: I analyzed the mechanics of the original record-player setup to isolate core functional variables: rotational speed, load-bearing requirements, and rotational smoothness.

  • The Engineering Challenge: The original setup suffered from severe instability and mechanical slip. I researched alternative industrial rotational systems, focusing on low-profile bearing layouts that could provide a completely flat, wobble-free rotation under varying object weights.

3

Modeling and protoyping

  • Spatial Layouts: In CAD, I modeled and evaluated different physical arrangements, integrating sourced off-the-shelf components (like standard casters and an outer gear band perimeter) to keep the footprint minimal.

  • The Integration Challenge: Programming the Arduino controller required fine-tuning the bidirectional servo motor’s acceleration curves; sudden stops caused lightweight scan objects to slide off the table, ruining the 3D capture.

  • Prototyping Around Components: I iterated a custom 3D-printed enclosure to protect the electronics while maintaining a precise mesh distance between the drive gear and the table's perimeter teeth.

3

Modeling and protoyping

  • Spatial Layouts: In CAD, I modeled and evaluated different physical arrangements, integrating sourced off-the-shelf components (like standard casters and an outer gear band perimeter) to keep the footprint minimal.

  • The Integration Challenge: Programming the Arduino controller required fine-tuning the bidirectional servo motor’s acceleration curves; sudden stops caused lightweight scan objects to slide off the table, ruining the 3D capture.

  • Prototyping Around Components: I iterated a custom 3D-printed enclosure to protect the electronics while maintaining a precise mesh distance between the drive gear and the table's perimeter teeth.

4

Sourcing & vendor handover

Vendor Vetting: I negotiated with local machine shops capable of producing the custom structural components efficiently without demanding massive minimum order quantities.

  • The Manufacturing Challenge: To prevent communication errors regarding tolerances, I generated finalized production CAD files and clear 2D technical drawings for the CNC-machined components, alongside precise vector files for the custom top-surface graphic wrapper.

4

Sourcing & vendor handover

Vendor Vetting: I negotiated with local machine shops capable of producing the custom structural components efficiently without demanding massive minimum order quantities.

  • The Manufacturing Challenge: To prevent communication errors regarding tolerances, I generated finalized production CAD files and clear 2D technical drawings for the CNC-machined components, alongside precise vector files for the custom top-surface graphic wrapper.

Industrial Architecture & Materials

  • Premium, Durable Construction: Machined the primary top and base disks from black HDPE, delivering a sleek, professional matte aesthetic that protects internal components from workshop impacts and liquid spills.

  • Kinematic Stability: Implemented a triple-caster array paired with a central cylindrical bearing to ensure perfectly concentric, wobble-free 360-degree rotation during camera calibration.

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Caption: Technical cross-section showcasing the cylindrical bearing alignment, caster placement, and the HDPE structural assembly.

Electromechanical Integration

  • Cohesive Shape Semantics: Enclosed the Arduino and servo motor in a custom 3D-printed housing, utilizing curved geometries that wrap organically around the circular table footprint.

  • Positive-Drive Gearing: Engineered a custom 3D-printed gear head that meshes directly with an outer toothed gear band to completely eliminate mechanical slip during programmatic rotation.

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Caption: Close-up CAD view of the curved motor enclosure, detailing the tight mesh tolerances between the 3D-printed drive gear and the table perimeter.

Functional UX & Branding

  • Deterministic Tracking Interface: Integrated a high-contrast, scratch-resistant vinyl decal featuring geometric location markers that give the vision software instant coordinate references, even for partially occluded objects.

  • Embedded Identity: Positioned premium CapSen branding directly on the top surface, ensuring maximum brand visibility during client deployments and inside software viewports.

Were the challenges met?

Production in-scalability

Commercial viability

Reflections

What went well

Interdisciplinary Execution: Bridging industrial design with basic mechatronics (Arduino programming + gear kinematics) allowed me to deliver a fully functional, self-contained hardware solution without bottlenecking the core software team.

  • Smart Cost-Efficiency: Utilizing a hybrid production model—combining outsourced local CNC machining with rapid in-house 3D printing—kept tooling costs at absolute zero while scaling production volume.

Working with manufactureres

What could be better

Improvements to be made to the product if mass produced, but served its purpose at low volumes. Not very professional to include a 3D printed part.

What could be better

Improvements to be made to the product if mass produced, but served its purpose at low volumes. Not very professional to include a 3D printed part.