Fall Protection Device, Simulation, and Stamping Die example

Shows off various complex and interestingly designed parts that fit together to make a working unit, in this case, a fall protection device that even upon mechanism failure (frozen spring, rusted shut shaft, etc) will lock the cap into place and prevent a fall through clearances and a cam-like interaction between the teeth and the cap itself. Example of using SolidWorks simulation and design studies to optimize a stop cap/pawl design. The initial design started with 0.035" deformation at the tip upon loading. After a quick design study and before any final polishing was done, I got it down to 0.005". The new design also had looser allowable tolerances, weighed less, and would be easier and more cost effective to machine/stamp. Exploded and assembled version of a misc. metal stamping die. Design for single stage, low tonnage press (hand pump or small hydraulic).