The PolarFlow Optics team recently reached a significant milestone in their journey – the Final Design Review on Tuesday, April 23rd. This momentous occasion marked the culmination of two semesters of dedicated work and collaboration.

In attendance were our esteemed liaison engineers from Johnson & Johnson Vision, who have been integral partners throughout this process. With anticipation and pride, the team presented a comprehensive overview of all that had been accomplished, showcasing the evolution of our project from concept to reality.

One of the highlights of the presentation was the display of 3D printed iterations of our prototype, providing a tangible representation of the progress made. Alongside this, the final prototype itself stood as a testament to the team’s innovation and perseverance.

Crucially, the testing results from the Netherlands facility provided concrete evidence of the effectiveness and reliability of our solution. This data served to validate our efforts and reinforce the confidence in our design.

As the presentation drew to a close, the team compiled all their hard work, insights, and recommendations into a comprehensive final report. This document not only encapsulates the journey of PolarFlow Optics but also serves as a roadmap for future endeavors in the field of optics and innovation.

However, it wasn’t all about work – the team seized the opportunity to celebrate their achievements and foster camaraderie with a well-deserved team bonding activity. What better way to unwind and reflect on a successful year than indulging in some delicious Tuesday Tacos at Cantina?

The Final Design Review wasn’t just a conclusion; it was a celebration of collaboration, dedication, and ingenuity. As the PolarFlow Optics team looks towards the future, they do so with a sense of accomplishment and excitement for what lies ahead.

Below, you can see a picture of our team after FDR!

Figure 1: picture of PolarFlow Optics team with their coach, Dr. Butler

Promotional video:
https://youtu.be/HivtrQrrcQM

Poster:

This week, our team achieved several key milestones in the development of our new pneumatically heated air jacket system. After months of design work, we completed the comprehensive Final Design Report, detailing all aspects of the jacket from materials and construction to heating mechanisms and control systems. This report will serve as the master reference as we move into manufacturing and product launch.

Our testing efforts also hit a major stride this week with field trials conducted at our facilities in the Netherlands. The core pneumatic air jacket technology was put through its paces, as was the integrated heating system comprising a network of flexible heaters woven into the jacket lining. All tests yielded positive results in line with our design specifications. We also finalized the official Testing Manual which will govern all future quality assurance protocols. Rounding out the week, we completed a promotional poster and video showcasing the jacket’s innovative features and benefits.

Fig. 1 Jacketed nozzle being tested

Below is a mesh of what we did as a team this week and the song The Final Countdown, in honor of this being the last blog.

(Verse 1) This week, our team, we soared so high, In the realm of innovation, we reached for the sky. Months of toil, design in our hands, Now we’re ready to unveil, across the lands.

(Chorus) It’s the final countdown, For our air jacket, heating bound. Design report’s done, it’s so profound, The countdown’s on, we’re victory bound.

(Verse 2) Testing, oh testing, we took it all in stride, In the Netherlands, our innovation did ride. Pneumatic prowess, heating system too, Passed with flying colors, our dreams coming true.

(Chorus) It’s the final countdown, For our air jacket, heating bound. Testing manual’s set, we’re renown, The countdown’s on, our glory crown.

(Bridge) Promotional poster, and video bright, Showcasing our jacket, in the limelight. Innovative features, benefits clear, With every step forward, we’re drawing near.

(Chorus) It’s the final countdown, For our air jacket, heating bound. Poster’s up, video’s found, The countdown’s on, we’re breaking new ground.

As the semester draws to a close, it’s time to reflect on the journey so far and focus on those crucial end-of-semester milestones. For many students, this means completing test plans, finalizing design reports, organizing simulation files, and putting the finishing touches on promotional materials. In this blog post, we’ll explore each of these tasks and discuss strategies for successfully navigating them.

Completing Test Plans: Ensuring Quality and Reliability
Test plans are essential for verifying the functionality and reliability of a project. They serve as a roadmap for conducting tests, recording results, and identifying any issues that need to be addressed. As you approach the completion of your test plans, it’s important to ensure thoroughness and accuracy.
Begin by reviewing your project requirements and specifications to determine the critical areas that need to be tested. Develop a detailed test plan that includes specific test cases, testing procedures, and success criteria. Collaborate with your team members to divide responsibilities and allocate resources effectively.
During testing, document your findings meticulously and communicate any issues promptly to your team. Prioritize resolving critical issues first and allocate sufficient time for retesting and validation. By completing your test plans diligently, you’ll ensure the quality and reliability of your project deliverables.

Finalizing Final Design Report Draft: Capturing the Essence of Your Project
The final design report is a comprehensive document that outlines the objectives, methodologies, results, and conclusions of your project. It’s a culmination of months of hard work and innovation, and its quality reflects the professionalism and expertise of your team.
As you finalize your final design report draft, pay close attention to its structure, clarity, and coherence. Ensure that each section flows logically and contributes to the overall narrative of your project. Review your technical content rigorously, verifying the accuracy of data, analyses, and interpretations.
Don’t forget to incorporate feedback from your peers, instructors, and mentors to enhance the quality of your report further. Address any comments or suggestions thoughtfully, demonstrating your commitment to continuous improvement. Ultimately, your final design report should showcase the significance and impact of your project effectively.

Organizing Simulation Files for End-of-Semester Deliverables: Streamlining Your Workflow
Simulation files play a crucial role in many engineering and scientific projects, enabling the modeling and analysis of complex systems. As you prepare for end-of-semester deliverables, organizing your simulation files efficiently can save time and reduce errors.
Start by establishing a clear folder structure that reflects the hierarchy of your project and facilitates easy navigation. Use descriptive file names and include relevant metadata to enhance searchability and traceability. Consider implementing version control systems such as Git to track changes and collaborate effectively with your team.
Regularly backup your simulation files to prevent data loss and ensure continuity in case of unexpected events. Verify the integrity of your files periodically and address any discrepancies promptly. By maintaining a well-organized repository of simulation files, you’ll streamline your workflow and improve productivity.

Further Editing for the Promotional Video of Your Project: Crafting a Compelling Narrative
A promotional video is a powerful tool for showcasing the innovation and impact of your project to a broader audience. As you refine your promotional video, focus on crafting a compelling narrative that captivates viewers and communicates your key messages effectively.
Start by identifying the core themes and highlights of your project that you want to feature in the video. Develop a storyboard or script that outlines the sequence of scenes and the narrative arc of your video. Incorporate engaging visuals, animations, and testimonials to bring your project to life and resonate with your audience emotionally.
Pay attention to pacing, transitions, and audio quality to maintain viewer engagement throughout the video. Seek feedback from diverse perspectives to ensure that your video is accessible and resonates with your target audience. By investing time and effort into further editing, you’ll create a promotional video that amplifies the impact of your project and leaves a lasting impression.

Conclusion: Embracing the Final Milestones with Confidence
As you embark on the final stretch of the semester, embrace these end-of-semester milestones with confidence and determination. By completing test plans diligently, finalizing design reports thoughtfully, organizing simulation files efficiently, and further editing promotional materials creatively, you’ll ensure the success and impact of your project. Remember to collaborate closely with your team, seek feedback proactively, and celebrate your achievements along the way. With perseverance and teamwork, you’ll navigate these milestones successfully and emerge stronger and more resilient than ever before.

Figure 1: a figure from our lab manual showing how to properly assemble PolarFlow Optics design

As we approach the culmination of an intense semester and the completion of our senior design project, the PolarFlow Optics team is proud to announce significant strides in our journey towards creating an innovative solution in the realm of ocular technology. With the end in sight, it’s time to reflect on our progress and share some exciting updates.

Final Prototype Design Sent to Johnson & Johnson Vision

One of the major milestones achieved by our team recently was the completion and mailing of our final prototype design to Johnson & Johnson Vision in Ireland. Our liaison engineer will now oversee the final testing phase, ensuring that our device meets the rigorous standards set by Johnson & Johnson Vision.

Prototype Inspection Day: A Showcase of Progress

Another highlight of our recent endeavors was the Prototype Inspection Day, where we had the opportunity to present our work to a panel of judges. This event provided us with invaluable feedback and insights as we fine-tune our design in preparation for delivery. Our presentation showcased the evolution of our project, from initial concepts to the intricacies of our final design.

Iterative Development and Simulations

Throughout the semester, our team has meticulously refined our prototype, focusing on every detail to ensure optimal performance. We have explored numerous iterations of nozzle designs, leveraging simulations to assess their efficacy and refine our approach. These iterative processes have been instrumental in shaping our final product, allowing us to overcome challenges and optimize functionality.

Discussion and Collaboration: Key to Progress

Central to our success has been the spirit of discussion and collaboration within our team. We have engaged in thorough discussions on control mechanisms, exploring various options to enhance precision and usability. Additionally, we have evaluated different materials for the suction tube, seeking to maximize durability and performance. These deliberations have paved the way for informed decisions and continuous improvement.

Looking Ahead

As we enter the final stretch of our senior design project, the PolarFlow Optics team remains committed to delivering a solution that pushes the boundaries of ocular technology. With our prototype in the hands of Johnson & Johnson Vision for testing and feedback from Prototype Inspection Day guiding our efforts, we are poised to make our mark in the field. The journey thus far has been challenging, yet immensely rewarding, and we are eager to see our vision come to fruition.

In conclusion, as we reflect on our progress and achievements, we extend our gratitude to everyone who has supported us along the way. Whether it’s our team members, faculty advisors, or industry partners, each contribution has been invaluable. With determination and perseverance, we are confident that the PolarFlow Optics project will leave a lasting impact in the realm of ocular technology.

Stay tuned for more updates as we embark on the final stages of our journey. Together, we are shaping the future of vision care.

Figure 1: depiction of our prototype being mailed to our liaison in Ireland

This week was pivotal as we prepared for the Prototype Inspection event, where our focus was on succinctly presenting our deliverables while highlighting the journey from problem identification to solution implementation. We focused on addressing challenges such as nozzle occlusion and temperature regulation deficiencies inherent in the intraocular lens (IOL) manufacturing process. Our solution comprised iterative design enhancements, including an optimized coolant nozzle and chip removal assembly, aimed at enhancing operational efficiency.

This week we conducted new simulations, drilled holes into our heat jacket, grinded the newest nozzle for the heat jacket, and refining the newest nozzle for precision. As we approached the event, we remained open to feedback, recognizing it as a catalyst for future enhancements and continuous improvement in the realm of IOL manufacturing thermal management optimization.

Here is a poem to reflect our week:
In preparation for the Prototype Inspection Day,
We worked tirelessly, come what may.
Drilling holes in heat jackets with care,
Grinding nozzles to perfection, a task so rare.

Simulations ran, each prototype refined,
Aiming for excellence, with every design combined.
Our journey from problem to solution, we trace,
In poetic rhythm, our progress we embrace.

At the event, we stood proud and tall,
Presenting our work, answering the call.
Feedback welcomed, for future strides we yearn,
In the realm of thermal management, it’s our turn.

Image 1: Grinded Newest Nozzle for the Heat Jacket

TWO NOZZLE DESIGNS COMPLETE:

For our control system developments the Novus controller has been delivered, and despite difficulties with the user manual, an electrical engineer will assist with setup and preliminary testing. Testing is scheduled to start upon receiving the thermocouple. The testing will involve assessing the controller’s self-tuning capabilities by integrating it with heating pads and the thermocouple. A power supply cord is also being delivered to facilitate the testing process.

The testing will take place soon and will involve sticking the thermocouple and heaters to an aluminum piece (to mimic the nozzle) in a freezer or in an ice bucket to ensure below freezing temperatures. This will then test the controller’s ability to proportionally heat the metal to above freezing.

Regarding waste removal improvements, efforts to manufacture a suction tube out of polyurethane faced obstacles. However, testing with higher-strength plastics such as Nylon, UHMW Polyethylene, and PEEK showed promising results. Moving forward, the focus will be on testing the rigidity of the polyurethane tube when attached to a vacuum and performing adhesion tests with polyetherimide, PEEK, and Nylon.

Greetings! This week, our focus on project advancements resulted in the successful completion of the FDR Outline, providing a crucial roadmap for our upcoming efforts. Our commitment to innovation shines through in the refinement of 3D printing processes, with multiple iterations of the suction tube featuring new tolerances. The manufacturing of the heated jacket is well underway, as seen from the pictures below, and we’ve submitted the air jacket design for metal 3D printing, promising enhanced quality. Exploring new, easily manufacturable materials for the suction tube further streamlines our production processes. As we head into spring break, the team is energized and ready to tackle the exciting challenges that await us upon our return.

Please enjoy the following haiku!

FDR’s roadmap blooms,
Guiding us through innovation,
A journey foretold.

Suction tubes iterate,
Dancing with new precision,
3D dreams take shape.

Heated jacket hums,
Manufacturing magic,
Threads of progress weave.

Air jacket takes flight,
Metal’s embrace, a story,
Quality elevated.

New materials sing,
Suction tube’s soft manufacturing,
Effortless creation.

Spring break whispers near,
A moment to pause and breathe,
Dreams linger, unfurl.

Greetings! During our presentation to the QRB2 committee this week, we showcased our efforts to enhance the manufacturing process for intraocular lenses (IOLs). Addressing issues like coolant nozzle occlusion and waste removal system clogs, we introduced innovations such as internalized flow paths and heat jackets. Our simulations and testing revealed significant improvements in flow uniformity and speed. Successful adhesion tests with Polyurethane demonstrate our commitment to comprehensive solutions. Looking forward, our critical path for Spring 2024 outlines our timeline for completing simulations, manufacturing prototypes, and conducting testing. Despite risks like challenges in integrating a PLC, we remain dedicated to collaboration and innovation as we redefine optical manufacturing. This week we also 3D printed our new nozzle itteration and bracketry system as seen in Image 1. Stay tuned for updates as we push the boundaries of excellence at PolarFlow Optics.

Image 1: 3D prints for nozzle, heater jacket, and bracketry

Greetings from the PolarFlow Optics team! This week has been incredibly productive for us as we dive deeper into our testing phase. We’re excited to share our progress with you as we continue to innovate in the realm of optics.
Our testing journey kicked off with an initial trial of our inner nozzle. To conduct this crucial test, we collaborated with the University of Florida’s Aero Lab, utilizing their air compressor machine. This allowed us to simulate real-world conditions and assess the performance of our inner nozzle design outside of simulations.
In another significant development, we received the elastomer sample from our Sponsor. We have started working on separating the elastomer (transparent material) from PMMA (blue material), depicted below.

Figure 1: Elastomers and PMMA stuck together received from Sponsor.

As we reflect on the accomplishments of this week, we’re energized by the progress made and the challenges overcome. Our focus remains unwavering as we march forward, driven by a shared commitment to excellence and innovation. In the coming days and weeks, we eagerly anticipate further breakthroughs and milestones that will propel us closer to realizing our vision for PolarFlow Optics.

In Week 20 of our project, significant progress has been achieved in advancing the Optoform 40/60. Our focus has centered on thorough testing preparation, including the design of a specialized test ring for nozzle assembly evaluations. Precision machining of essential components, such as tubes and reducers were done this week. Additionally, we’ve iterated on design elements, enhancing features like the vacuum tube adapter mechanism and refining nozzle geometry for optimal performance. Collaborative efforts have been instrumental in moving us forward, and we eagerly anticipate conducting comprehensive testing in the upcoming weeks. Furthermore, morale received a boost this week with a team bonding event at Salty Dog, fostering a stronger sense of motivation within the team.

Picture: Team Bonding