1. PORTFOLIO
Ken Orr –Design Engineer/Owner

2. Services
 3D design engineering utilizing Pro/ENGINEER
• Complex Surfacing and Assemblies
• Sheetmetal
• Mechanica, static only (structure & thermal)
• Drawings (to ASME-Y14.5M standards)
• Packaging studies
• Simple fixture design
• Plastic part design (an Orrbit Design specialty)
• Project Management
 Prototyping
• SLA or Objet
• Urethane Castings
• CNC machining
• Finish Work (hand crafting, painting, etc.)

3. Example – Patio Umbrella
***Patent Pending***
 110V Powered Patio
Umbrella
• Design included
electrical housings,
crank mechanism, and
assembly.
• Prototypes supplied
using SLA/Objet
masters to generate
silicone molds for
multiple cast parts.

4. Example – Cordless Phone
 Cordless Phone and
charging base
• Class-A complex surfacing
• Generation of Front Cover,
Rear Cover, Battery Cover,
Display Window, Keypad,
Belt Clip for Injection
molding
• Integration of electronics
with display lens, earpiece
connector, and battery
charging contacts

5. Example – Lawn Edging
 Wheat & Rock simulated Lawn Edging
• Integrated intricate designs for injection molding
utilizing scan data with solid modeling
• SLA prototypes generated, and painted with
production intent colors

6. Example –Remote
 Spa Remote Control
• Class A surface
• Front Cover, Rear Cover,
Battery Cover, Tactile
Keypad, Display Lens,
Rubber Key, Wall Plate
• Integrated Electronics
includes display, thin tactile
keypad top keep water proof
• Prototypes supplied using
SLA/Objet masters to
generate silicone molds for
multiple cast parts in a
urethane material. Keypads
were prototyped by keypad
manutacturer

7. Example – Gateway
 Gateway for Schlage lock
system
• Class A surface for black
injection molded parts
• Front Cover, Rear Cover,
Battery Cover, Keypad
w/integrated light pipes
• Integrated Electronics
included PCB w/vertical
mount switches, RJ45 jack &
battery w/light pipe out front
• Prototypes supplied using
SLA/Objet masters to
generate silicone molds for
multiple cast parts in a
urethane material.

8. Example – Caulk Gun
 Caulk Gun for 5.5oz tubes
• Class A surface
• Right & Left Covers, Tray with
motorized screw feed
mechanism (Acme thd) with
release trigger & gear system
to drive feed mechanism
• Integrated Electronics & battery
pack
• Prototypes supplied using
SLA/Objet masters to generate
silicone molds for multiple cast
parts in colored urethane
Actual prototype

9. Example – Tubs
 Bath & Spa tubs designed
for Vac Forming from high
gloss sheet stock
• Class A surfacing
• Continuity of rounds was
crucial to this process
• Non skid on floor w/jet &
drain locations

10. Example – Bench
 KLM Bench, commercial
seating (8 person shown)
• Legs designed for
aluminum casting w/high
gloss polished finish
• Designed to support up to
450lbs per seat

11. Example – Water Cannon
 Toy Water Gun
• Class A surfacing
• Hand run crank to pump
water
• Base designed to adapt to
a boat or dock
• Nearly 45 degrees of tilt
front/back and swivels full
360 degrees.

12. Example – Seat Back Sail
 Sail for office furniture
side chair
• Class A surfacing
• Each intersection had to
be cut away and a surface
blend created to meet
designers requirements

13. Example – Swim Device
 Wrist, Ankle & Head
devices to monitor
swimmers
• Units are required to be
water proof to IP68 & air
tight to 0atm in a cargo hold
of a plane with no change in
the unit when held in your
had at ground level.
• Top cover is an inset molded
part with a 60 durometer
Santoprene material to allow
activation of 2 switches.

14. Example – Medical Device
 Medical device
• Package electronics into
small enclosure with 3
switches
• Top cover is an inset molded
part with a 40 durometer
Santoprene material to allow
activation of switches.
• Back cover is formed metal
stamping

15. Example – Mechanism Cover
 Mechanism Covers
• Develop new mechanism
covers for an office furniture
chair
• Worked closely with
Industrial Designers to
capture design intent
• Created skeleton model to
ensure proper form between
upper and lower cover

16. Example – Chair Seat Development
 Chair Seat
• Develop new seat for a new
chair
• Create structural plastic
lower that mounts to cylinder
mounting plate. Worked with
FEA to determine best rib
structure and wall thickness
• Create release lever for
fore/aft adjustment and a
cover for the “no option”
option

17. Example – Chair Back Frame
 Chair Back Frame
• Develop new back frame for an
office furniture chair
• Worked closely with Industrial
Designers to develop best ProE
class-a surfacing
• Parts had to have mating
surfaces for a sonic weld
operation, this required the
sharing of data between files
(publishing geometry)
• Because of the sharing of data
between file, the best method
was use of a skeleton model

18. Example – Cervical Spine Display
 Cervical Spinal Display
Model (C4-C6)
• Develop 2ft wide cervical
bone models for use in a
medical expo
• C4 and C5 to rock 10degrees
left/right
• Design of motion mechanism
to fit within the main body of
the bone

19. Contact
 Orrbit Product Design LLC
• Ken Orr
• 243 129th Ave.
• Holland, MI 49424
• 616.240.7200
• ken.orr@orrbitdesign.com
• www.orrbitdesign.com