High-Impact Containment Enclosure Box / Mechanical Design Lead
Background / Goal
This project involved designing and building a custom polycarbonate containment enclosure box to safely house high-velocity projectile testing inside a Split Hopkinson Pressure Bar (SHPB) system. The goal was to mitigate risk from internal material fragmentation during dynamic impact events. As Mechanical Design Lead, I created a detailed parts list from McMaster-Carr and imported all components into SOLIDWORKS — including aluminum brackets, polycarbonate panels, latches, and pneumatic accessories. I then designed the full CAD assembly, iterating through fits and interferences before guiding the team through fabrication and assembly. The final product is a fully enclosed, modular box designed to withstand repeated internal impact while allowing full visual monitoring and sensor access.
Project Overview
Final Product
Initial Design (Exploded)
CAD Design / Simulation
Isometric View
Back View
Top View
Side View
SOLIDWORKS Pressure Simulation
Validated structural integrity under applied internal pressures, confirming the enclosure’s ability to withstand expected loads.
Manufacturing / Assembly
Bandsaw
Drill Press
Description
Fabricated components using a combination of machining and precision fitting techniques to ensure structural accuracy and safety. T-slot aluminum extrusion was cut to length using a bandsaw, and polycarbonate panels were drilled on a drill press, maintaining correct hole tolerances for flush mounting and proper alignment with the frame. Fastening operations included accurate torque application on brackets, gussets, and cam latches to guarantee rigidity. Dimensional accuracy was verified with calipers and square alignment tools, ensuring that tolerances were consistently met across all assemblies.
Test Trial 1
Test & Integration
Impacted Projectile Bar
Ongoing Work
We are actively conducting further SHPB test trials using various aerospace materials to analyze their dynamic response under high strain rates. More tests and data collection are underway.