John Morzfeld

Spring Lake, MI
231 215 5139
johnmorzfeld@yahoo.com
Design Portfolio 2012 2014
This purpose of this document is to showcases my design skills and provide descriptions of the design
projects as needed. Thank you for taking the time to review my work.
All designs done in Solidworks

CUSTOM INTAKE MANIFOLD

This is a custom intake manifold used for racing engines. The intake itself is made up of 4 aluminum parts.
An upper, lower and 2 runners. The 8 intake locations can be changed for different engines. I have already
cut 2 of these out of aluminum 6061 billet. Along with the design of this product, I designed the holding
fixtures to used to manufacture it. An interesting part of this design is the hidden seem-less radius where the
runners meet the drop tubes.

CUSTOM VALVE COVERS

These are a pair of custom valve covers machined out of aluminum billet. A notable part of this design is the
undercuts which are machined with a slotting endmill. These are machined as a pair in 2 set ups.

CUSTOM MOTOR PLATES

Using Solidworks associated features allowed me to lock down critical dimensions and alter the custom
motorplates for each car without having to start over with each design.

MOTOR PLATE ASSEMBLY

TURBOCHARGER PRECHARGER COWL

Using the associative properties of Solidworks I designed different cowls for different pro-charger units.
These units are machined out of aluminum billet. Looking at the cross section you can see work holding can
be a challenge. These cowls are machined on a vmc in 3 set ups.

TURBO VOLUTE
Most turbo covers are cast. This one is 3 pieces and was machined out of billet aluminum.

GOPRO 360 DEGREE 3D PRINTED CAMERA HOUSING

This project was fun. I had to design a housing that would hold 6 GoPro cameras along with the circuitry
and data ports. This was 3D printed in order to save my client money in manufacturing. The 3d print
worked excellent and really made this project feasible. I used threaded inserts to bolt all the pieces together
and act as the threads for a tripod.

SPORTING GOODS AND FIREARMS

This is a couple of lower receivers for the AR platform. They are in full production and available from my
clients manufacturing company. I provided the designs in collaboration with the client and produced
manufacturing blueprints.

BABY SUNGLASSES
This project really showcases the power of associative designing in solidworks.
These sunglasses are all properly drafted in order to be molded. They also all have the proper slot to accept
optical grade curved lenses. What is very cool about this design is the fact that each sunglass design on the
left side is made by simply changing one 2d shape. If you go back in design time, and change the shape of
the 2d lens, the entire frame and lenses auto updates and rebuilds itself into a moldable frame. Now if we
took and added the plastic injection mold into this associative design, we could literally design 100 different
sunglasses and molds in an hour or so.

CONSUMER ELECTRONICS HOUSING

For this project I was provided with an artist rendering of the clients concept. I took this concept and turned
it into a full blown design for manufacturing. Using proper wall thickness, and strength ribs I designed this
to be injection molded. We 3d printed our prototype and tested it for fit with the electronics. This is an
unusual design because the caps doesnt use screws to attach itself to the back, rather it uses snaps. This
eliminates manufacturing time. However contingencies were made in the design to incorporate a screw
assembly should real world testing direct it. By designing this contingency into the part, the changes could
be made to add the screws without breaking the design. This product is currently in the marketplace.

DESIGN FOR MOLDABILITY

This was a project that came to me as a solid mass. I had to hollow it out in order to be molded, following
plastic injection molding standards. I also working with the client to make design suggestions and
engineering changes. The molds for this project are scheduled to be built in Canada this year.

JEWLRY BUTTONS
I helped a client realize their product by coming up with a way to attach a cap to the top button of a dress
shirt. The requirements were to have the button work with the cap on or off. By making the button a
threaded on the OD, it allows the cap to be screwed onto the button. All of the logos are actual cad
geometry and not just jpgs. I took the jpg of the logo, ran it through inkscape and created dxfs of the logo
and extruded it into the cap. I also made 6 buttons as prototypes for the client using a .010 diameter
endmill.

MY FIRST PATENT
This is a front take down pin for an AR. We needed to find a way to limit the pivot angle distance when
opening an AR. This has been awarded a provisional patent and is waiting for a redesign to make it better.

RANDOM PRODUCTS
These are just a random collection of some of my designs.

PLASTIC INJECTION MOLD DESIGN

These are just some small easy mold designs I made. The picture on the bottom right is the type of small
precision molds I am capable of building.

A COUPLE CLIENT REVIEWS

Thank you for taking the time to review my work!