Next-Gen Baggage Scanner

Modular, serviceable platform designed for faster manufacturing and reduced maintenance costs

This project focused on developing a parametric baggage X-ray scanner platform, designed to replace a legacy machine and scale into a full family of tunnel sizes from a single configurable base model.

- Legacy machine required 8+ hours for routine maintenance due to poor access
- 200+ unique parts increased manufacturing cost by 40% and lead time by 6 weeks
- Outdated appearance and ergonomics
- Each tunnel size required complete redesign (3-4 weeks engineering time per variant)

Challenge 1: Maintenance Access

Designed modular subassemblies with quick-release panels
Reduced maintenance time from 8 hours to 2 hours (75% improvement)
Challenge 2: Manufacturing Complexity
Sheet metal simplification: Reduced unique parts from 200 to 85
Standardized fasteners across entire product line
Created repeatable modules for faster production Challenge 3: Tunnel Size Variants
Parametric master model with top-level parameters
One prototype design
multiple production sizes Challenge 4: Modern Appearance
Cleaner industrial design
Improved ergonomics for operator interface

3D MODELING & PARAMETRICS:
- Configurable master model with top-level parameters
- Modular assembly structure (replaceable subassemblies)
- Design rules for automatic scaling across tunnel sizes
MANUFACTURING DOCUMENTATION:
- Complete drawing package with GD&T
- BOM structure supporting product variants
- Manufacturing-friendly detailing (bend relief, standard hole patterns, shared brackets)

DESIGN FOR ASSEMBLY:

- 87% faster variant creation: 2 days vs. 3-4 weeks per new tunnel size
- Eliminated redesign work: Parametric model auto-generates new sizes
- 75% reduction in maintenance downtime (from 8 hours to 2 hours)
- Better production readiness (repeatable modules, simplified fabrication)