Apprenticeship Projects

Porous Concrete (v3) (1).mov

Nov 2025: Life Cycle Analysis

As part of our Sustainable Engineering module, our group developed a Life Cycle Analysis (LCA) on porous concrete.

The video and scripting was done by myself. We all worked together on the research, including using Ansys Granta Edupack for data.

The brief gave us a time limit of 5 minutes, so this one was tricky to fit in. But, I really enjoyed the process, including booking a studio and equipment to film, and learning DaVinci Resolve (video editing software) to do this.

July 2025: CNC Machining

Having completed the CNC machining module, I have picked up a lot of skills, involving Hypermill software and supporting Solidworks software, but also including real machining.

I felt like I gained a great foundational understanding of how to operate and program a CNC machine. The software overall I felt became quite intuitive, and the quirks I learned to work around. The assessment went well, and I had little issues with completing it.

Learning new software and techniques benefits me to make me more adaptable, which I believe showed here with the speed that I was able to pick both software packages up.

For further improvement, I would like to machine more to understand the implications and workarounds for more sophisticated kinds of features and machine types. Working with 3 and 4 axis machines in person broadened my understanding and skillset in manners I would not have anticipated. Also, working on machines themselves taught me lots about the things you don’t simulate, such as clamping the part correctly, setting tools up with correct measurements and calibrating the zero for each axis.

Overall I learned lots during this module, and Andy did a great job teaching us how to implement our skills on the computers into real life products.

VID_20250717_103153.mp4

4-Axis Machining

A bandsaw would've been nice here...

Included personalised engraving (0.7mm)

Tool presetter to calibrate tools accurately

Running a program on the Haas 3-axis machine to finish the cubes

6 cubes made

VID_20250720_143545.mp4

After it was polished, this is what it looked like.

May 2025: Robotics!

I applied the skills, knowledge and behaviours which I successfully developed throughout to enable me to complete a variety of competency assessments. Some of these included making a manual for complete operation and safety of the robot, a welding simulation, assembly of a robot, stacking blocks and more.

Most of our programming was done through point-to-point, which I learned is the preferred method to programming today due to it simplifying the programming of complex movements. We used industry standard ABB robots along with their tablet interface and software.

Overall, this was super fun and it taught me a lot about how the industry has moved towards automation, and what improvements can be made in the industry within programming and systems.

Probe Simulation (Automated)

Assembly (Automated)

Stacking

Mar 2025: Prototyping Project for work with EDF

(Apologies for the vagueness - the work is sensitive and I cannot share too much!)

This project involved producing prototypes. It was imperative to maintain dimensional accuracy, whilst adhering to specific model requests, all whilst improving print quality. This project involved working with quite a new material to me which required tweaking of advanced slicer settings to get it right. My personal 3D printing experience really came into use with this one, and my experience with tools.

What I learned

Time management
- Balancing time to different tasks throughout the day
- Print queue management
Adhering to the business' system and safety requirements
Costings
Printing techniques for different requirements
Building relationships with PMs

What my next steps are

Deliver tasks to agreed margins, schedule and quality
Take active steps to modify behaviour as a result of feedback and setbacks
Demonstrate flexibility
Disciplined and organised when approaching tasks
Work on a variety of tasks spanning different projects and clients
Experience different working environments
Gain industry knowledge of tools, technologies and systems

13.01.25 - 18.01.25: Davit Crane Rebuild

The Davit Crane is a 1:12 scale model, which failed whilst lifting a load greater than it was rated for.

For this project, two of us were tasked to:

-Disassemble

-Assess the failure that occurred

-CAD the new parts, considering changing how the part that is broke is loaded

-3D Print it

-Assemble it

This project taught me about working in a team to a deadline, including setting and allocating obtainable tasks.

Some of the parts & redesigns are shown here - fixing errors with tolerances or any design oversights.

Here I modified the CAD files to include a 3D printed bearing, which I used 6mm BBs for. I tried to reduce the gear ratio of the slew gear but due to never using Inventor's gear generator, making a worm gear proved to be much more of a learning curve than I thought I would. Maybe in the future!

30.11.24 - 14.12.24: Rainwater Harvesting

I am very happy to be involved in an external project, and although I was only involved in the building, I gained lots of skills along the way and met lots of great people. It may not look like much, but lots of preparation from society members over the years went into this project and being there to build it was very rewarding. I hope the people using the allotment find it useful! I would love to be involved in another project in the future, still sticking with sustainable engineering.

Sep 2024 - Nov 2024: CAD Projects

During my first 3 months of the apprenticeship, I worked towards completing the first module, which is in CAD, in EAL Level 3 Diploma in Engineering and Manufacturing Support Technologies. Here, I learned how to model, make drawings and assemblies to standards in Inventor.

Given drawings to follow, I was tasked with making various parts. Here I am showing the following:

Layshaft
Alloy wheels assembly
Oscillating piston assembly

We completed drawings of each part, and here I show the first one I did. The red is peer feedback, which was done on each drawing. This helped to iron out mistakes or bad habits.

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