Understanding user challenges
Manual conduit bending is a skill-intensive and physically demanding process that often leads to inconsistencies, rework, and inefficiencies on job sites. Existing automated solutions are typically bulky, expensive, and inaccessible for small teams or rapid prototyping environments. There is a need for a compact, cost-effective system that enables precise, repeatable conduit bending while reducing reliance on operator skill and physical effort.
I was responsible for designing the bending subsystem, with a focus on balancing performance, cost, and manufacturability. To address these challenges, I developed a mechanism incorporating a steel moment arm and pressure die, integrated with a linear actuator and coupler. This approach provided the necessary force and precision for bending operations while avoiding reliance on a large, high-cost motor. By leveraging the mechanical advantage of the moment arm and ensuring proper integration between components, I was able to maintain the project within scope and budget while still meeting the required functional performance
