Project Portfolio
Project case studies · Engineering capabilities · Historical presentation
Examples of Our Work
Project Case Studies
Design examples and project details from Ken Orr’s 2026 portfolio. Select an image for the full-size view.
Posterior Surgical Trainer
Developed with Encoris for training on the lower and middle spine, from the sacrum to T8. The battery-powered trainer combines an LED light with four cameras connected to presentation software. Camera mounts follow the spine’s lordotic curvature through side rails and a central glide. Construction combines a CNC-machined acrylic base, a vacuum-formed torso, cast urethane bone structures, and mounting blocks.
Indoor/Outdoor Sensor and Control
Injection-molded housings integrate an off-the-shelf motion sensor and lens with a visible LED. The design addresses water testing and UL 5VA flame requirements through housing path features and sonic-welded lens and light-pipe components. The lens subassembly uses the supplier’s seal and a weld ring.
Outdoor Sensor and Control
A clear polycarbonate molded component combines LED visibility with a light pipe for a light sensor, alongside an off-the-shelf motion sensor and lens. The vertical PCB connects to an existing cast aluminum housing. Material selection and O-ring seals address the project’s water and UL 5VA flame requirements.
Touch Screen Pocket Device
A handheld enclosure designed around repeated three-foot corner-drop requirements, a touch screen, a side power button, USB, and an infrared transmitter/receiver. Custom light pipes support the infrared function. The front and mid-frame capture the PCB and LCD, with Gorilla Glass and a locating frame supporting the display. A snap-on battery cover can disengage during impact and be refitted.
Air Monitoring System
An indoor/outdoor air-sampling unit uses screened openings and a fan to move cooling air through the electronics. A Peltier-equipped thermal box maintains the sampling temperature, while Wi-Fi antennas provide network communication. Interchangeable straps and a stand support table mounting or poles from 2.5 to 5 inches in diameter.
Refrigerator Produce Preserver
A refrigerator wall-mounted enclosure holds two packs of produce-preserving material. A suction cup allows removal for cleaning. The snap-together cover incorporates a molded hinge and top latch, with a separate latch component that accommodates a replaceable instruction card.
Further Details on Featured Projects
Atlas Task Chair Headrest
Developed with a local company and BeckFoley LLC for Herman Miller Aeron chairs. The mechanism provides fore/aft, height, and tilt adjustment, with an attachment designed for all three chair sizes. Collaboration with the industrial designer addressed smooth motion, clamping, and manufacturability.
Backcountry Ski
Developed with a Michigan company to combine cross-country and downhill use in a wide ski. Base scales help with climbing. The manufacturing direction used blow molding and threaded inserts for different bindings, with material, filler, and tooling choices developed alongside the molder.
Medical Camera
A wall-mounted camera enclosure for monitoring patients who need assistance. Design features include an Ethernet and control interface on the rear, a lower camera dome, upper ventilation, front speakers for staff communication, and security screws on the top and bottom caps. The dome material balances camera concealment with visibility.
EveryDrop Water Filter
A portable filter with a travel case, pitcher adapters, and a purpose-designed pitcher. The carbon combination filter includes a month indicator to track replacement. A twist-off top and light friction snap allow filter replacement, while the lower section uses a Santoprene overmold for grip.
Swim Monitoring Device
The 2026 portfolio adds a physical prototype view and states that finite-element analysis preceded tooling. The wrist, ankle, and head devices combine sealed electronics with an insert-molded Santoprene cover that allows switch operation. The project addressed IP68 water-resistance and pressure-change requirements.
Medical Device Enclosure
The newer presentation adds detail on the USB connection, LCD, and sealing around the three switches. The insert-molded Santoprene top cover supports switch operation, and the formed metal back cover snaps into place.
Engineering Background and Capabilities
From Ken Orr’s 2025 company presentation.
Ken Orr
Ken combines mechanical design engineering with manufacturing and production experience. His background includes a BS in Manufacturing Engineering from Western Michigan University with an emphasis toward mechanical engineering. He has operated an independent business since 2003.
His work serves office furniture, consumer electronics and products, automotive, medical, and air purification applications.
Product Design and Electronics Packaging
- Plastic part design for injection molding, vacuum forming, extrusion, and blow molding, with assistance sourcing tooling and molding.
- Class-A surfacing in Creo and SolidWorks, complex assemblies, sheet metal, packaging studies, and simple fixture design.
- PCB mechanical definition in collaboration with layout teams, switch selection and forces, connector and wire-harness interfaces, graphic overlays, and custom silicone keypads.
- Sealing and IP-rating considerations, assembly and detail drawings, and GD&T.
- UL-related design considerations including UL 94 flammability, indoor/outdoor and UV material specifications, and separation of high- and low-voltage components.
Prototypes, Analysis, and Production
- Prototype sourcing, procurement, and management for rapid prototypes, urethane castings, CNC machining, finishing, and soft tooling.
- Static structural and thermal analysis using Creo’s Mechanica module for early review of parts.
- Project management and collaboration with tooling and production suppliers to refine components, fixtures, manufacturing processes, and quality.
- Additional CAD and mechanical engineering support through established contacts, subject to scheduling.
Business address in the supplied presentations: 12330 James St, Ste H120, Holland, MI 49424.
Orrbit Product Design — Portfolio Presentation
This presentation contains only a small subset of projects that I have worked on, and I have selected projects that encompass my skill set the best. Feel free to contact me for more information.
Historical portfolio slides by Ken Orr. Select any slide to view it at full size. For current capabilities, see our engineering services.
Historical Project Portfolio
Selected projects described in Ken Orr’s portfolio presentation, published in 2013. These examples supplement the recovered website; they are not recovered text from its missing project page.
- Powered patio umbrella: Mechanical assembly, crank components, electrical enclosures, and cast prototypes.
- Cordless telephone: Sculpted housing surfaces, molded covers and keypad components, with electronics integration.
- Spa remote: Enclosure and controls developed around electronics, with urethane prototype parts.
- Commercial bench: Cast aluminum leg design for multi-person seating.
- Office chair components: Mechanism covers, structural seat design, and back-frame surfaces developed with industrial designers.
- Medical enclosure: Compact electronics packaging with switch-actuation features and a formed metal back.
- Cervical spine display: Enlarged anatomical models incorporating a concealed movement mechanism for exhibition.
Source: Ken Orr – Design Engineer/Owner, 2013 portfolio presentation