← Work
Mechatronics & Hardware
Precision-Motion Digital Twin
Sub-25-micron accuracy under load, and a failed 100 GB simulation rebuilt into a 34-second solve.
A physics-based digital twin — static, modal, and harmonic FEA — of a precision motion platform, predicting deflection, stiffness, and dynamic response before hardware exists.
I characterized sub-25-micron positioning under full load, mapped tool-point stiffness across all 6 DOF to isolate the governing compliance axis (3× softer than the stiffest), and halved deflection with a mineral/epoxy composite fill validated by a parametric FEA sweep. Then I rebuilt the geometry and meshing pipeline to turn a failed 2.7M-node, 100 GB solve into a converged 34-second run — fast enough for closed-loop iteration.