Latest News and Projects

Recent developments & projects at Frisella Design:

Automated Medical Component Work Cell

February 2016:  Frisella Design is developing a custom work cell that automates the application of a near field communication (NFC) tag to a medical device.  This continuous motion system will combine the functions of inserting, inspecting, printing, sterilizing and packaging for this device.

Robotic Printed Circuit Assembly System for Odd-Shaped and Short-Run Components

January 2016: Engineering has begun for a system that will eliminate need for manual insertion of odd-shaped and short-run components on a printed circuit board.  This leading-edge system features a 6-axis Epson robot that utilizes multiple vision cameras, custom control software and advanced component feeder technologies; this revolutionary work cell will help US manufacturers in our re-shoring initiative.

Flexible Robotic Assembly Work Cell

December 2015: We began the design, fabrication and integration of an assembly work cell utilizing a FANUC LR Mate 200iD robot.  This effort is unique in that the work cell has a modular design able to be deployed rapidly to a range of assembly applications.  This 3-stage system uses multiple vision cameras for precise assembly of high-end consumer appliance components.

Dual robotic work cell for medical assembly

July 2015: Frisella Design began a multi-robot fully automated work cell for the assembly of a plastic medical product.  Utilizing rotary indexing, servo actuators and two SCARA  robots to load, unload , dispense adhesive  and assemble  this  5 part  device , the result will  more than double  the production rates while reducing direct labor content.

Power transmission

June 2015: This month Frisella Design began analysis work on an electrical power transmission pole “repair kit”. Hundreds of thousands of power transmission poles are failing — the top 5-10 feet, due to age and poor sealing protection on the top end of the pole.  The system will take advantage of the fantastic strength to weight ratio of composite materials together with FEA simulation of 3D models.

Railway robot

April 2015: Frisella Design was contracted to deliver the Industrial Design, mechanical design and fabrication of the external enclosure of an autonomous robotic railway track inspection vehicle. The initial challenge  was aesthetics — how does this not look like a refrigerator  on wheels, while also complying with federal railway vehicle design regulations, sensor and radar locations not to mention weatherproofing the sensitive onboard electronics. The result has visual appeal, rugged composite panel design which provides access to the gear as well as innovative panel mounting scheme designed to keep out the elements.

Automated engine inspection machine

March 2015: Frisella Design was approached by a tier two automotive supplier to design and build an automated inspection machine which employs digital force sensing and servo motion control to inspect the outside diameter of an engine component to within .00010 of an inch. The inspection system runs at 20ppm on a component that requires 100% testing. The system eliminates the need for manual inspection and frequent calibration.

Automation project kickoff for Johnson Controls

November 2014: In November, Frisella Design will begin designing and building a metal forming work-cell that will nearly double throughput of one of Johnson Controls HVAC manufacturing lines.

Automated engine inspection machine

March 2015: Frisella Design was approached by a tier two automotive supplier to design and build an automated inspection machine which employs digital force sensing and servo motion control to inspect the outside diameter of an engine component to within .00010 of an inch. The inspection system runs at 20ppm on a component that requires 100% testing. The system eliminates the need for manual inspection and frequent calibration.

Automation project kickoff for Johnson Controls

November 2014: In November, Frisella Design will begin designing and building a metal forming work-cell that will nearly double throughput of one of Johnson Controls HVAC manufacturing lines.

Archery product design

November 2014: Our team is designing an innovative safety feature for our client, one of the leading companies in the archery industry.

Automated tape dispensing system

October 2014: Based on our previous experience in automated tape dispensing machine design, Frisella Design engineers have started this week on an automatic adhesive/masking tape dispensing system for a client that will enhance their manufacturing facility’s productivity.

Innovative work cell in fabrication phase

October 2014: Frisella Design is in the final stages of assembling a custom built work cell for a local manufacturer. This new machine will increase throughput and eliminate repetitive motion injuries for their workers.

Food packaging new product development

September 2014: As part of our  ongoing efforts in  the design and development of a new food packaging process, our team designed ,fabricated and shipped a custom thermoforming test system to a large New England food packaging manufacturer.

Medical robotics

March 2014: Frisella Design begins design and development on a medical product involving an innovative combination of micro-robotics and Doppler ultrasonic sensing.

August 2013: A food packaging manufacturer selected us to help develop a new food packaging  process that required a combination of experience that few engineering firms possess: precision tooling, automation, plastics processing and new product development. The elimination of the synthetic chemical "BPA" (Bisphenal A has unwanted hormone-like properties) in food/water packaging and storage applications is a hot topic in food packaging circles.  Frisella Design is working with one of the largest food packaging firms in in the U.S. in an effort to eliminate the use of BPA and other substances that may be harmful. This project is ongoing and the results to date have the client very excited.

Non-toxic thermoforming food packaging systems

February 2014: FrisellaDesign is in the final stages of development of a groundbreaking food packaging concept that pushes the capabilities of conventional thermoforming processes. VIEW >

Water treatment/chemical products design

July 2013: A manufacturer of water treatment and cleaning chemicals needing design concepts to make his products look more professional. His response after seeing the first 3D designs:  "In my wildest imagination I’d never have envisioned these designs. They are great!  Can’t wait to see more." The products are currently in development and should be completed shortly.

Design & prototyping of baseball pitching aid

February 2013: A sports training group came to us in February with the idea for a new baseball pitcher training aid. Pitchers have been using a drill called the "towel drill" for years (using a simple towel to help pitching follow-through) but this drill has been regarded recently as potentially harmful by orthopedic experts. The group had already prototyped their idea, but upon our review we discovered it wasn't practical to manufacture. After recommending a couple of alternative approaches we were able to eliminate 30% of the components from the original prototype.  We handed the client the new prototype and 2 days later he sent me a picture of that very same prototype in the hands of Justin Verlander of the Detroit Tigers.  Justin was the 2011 American League Cy Young winner!

Dental appliance for treating periodontal disease

January 2013: On the medical front we are moving into the second phase of a periodontal treatment device which uses "photo therapy" to treat periodontal infection. This second phase utilizes flexible light pipes along with silicone mouthpiece to direct near infrared light to affected tissue anywhere in the mouth.   VIEW >

Frisella moves to a new home in Florida

July 2012: Frisella Design LLC has expanded and moves in to larger quarters in Clearwater, Florida.

Automated warehousing system design

March 2012: Frisella Design LLC contracts with PDS Commodities of Century City, CA to develop key components to state-of-the-art, highly automated commodity warehouse system.

Crossbow product development

November 2011: Frisella Design continuing development work with a leading crossbow manufacturer developing "anti-dry fire" mechanisms and crossbow cranking mechanisms.   VIEW >

Hewlett Packard ink-jet cartridges

November 2007: as subcontractor for ATS systems is working on Hewlett Packard automation systems used for the manufacture of ink-jet cartridges.   VIEW >

Marine hardware products engineering

June 2007: Frisella Design was contracted by A-ccon Marine of Clearwater, FL to re-design a line of their high-end marine hardware products to reduce manufacturing costs while improving functionality and maintain the high aesthetic appeal of the product line.   VIEW >

Award-winning product design

June 2005: Mop-King was awarded most innovative product in the cleaning industry at a major trade show in France, based on our engineering and design work.

Mop-King cleaning systems

August 2004: Frisella Design is contracted to develop a line of commercial cleaning systems known as “Mop-King”.  This patented system would eliminate the use of the traditional “mop and bucket” in hospitals and other institutions

Aircraft turbine blade development for GE

June 2004: Frisella Design, under contract with GE Aircraft Engines develops an innovative solution that automates the roll forming operation of precision turbine blade manufacturing.