https://www.russellstanbery.com/lookbook daily 0.75 2021-05-11 https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620688850674-2JUBPY9UYH1SR8VJ34G7/IMG_9902.jpeg Gallery Montana - Big Sky Country, the Last Best Place, my home, my love. This is on a riverside beach outside of Missoula, the town I consider to be my second hometown. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620748594174-GAVWG57UXOU69PVQZBGN/IMG_6887.jpeg Gallery Sipping a beer at Darling Hill in East Burke, VT. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620687071189-0IUC8YTQJ05K9F2XHHF2/IMG_6292.jpeg Gallery Helena MT has some of the best trails and what a nice transport! Thanks Dad for lending me your 1971 Chevy C10. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620687165652-5AL2UYVA7N7W7P2VMXSD/camping.jpg Gallery Camping is one of my favorite outdoor activities, as it can bridge together all other outdoor activities. There’s nothing better than having a great day on the trails or in the water and then coming back to the campsite to enjoy a beer and cook a gourmet meal over the fire. If you need/have any ideas for Dutch oven meals, hit me up! https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620748359233-AQAG4RNR3VZAUM5F1ESB/IMG_5574.jpeg Gallery Friends + bikes = good times at Highland Mountain Bike Park in NH! https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620748410184-8RXR57504XNUMG4GRBXN/IMG_9138.jpeg Gallery Back wheel shenanigans on my dirt jumper. Haha my face in this photo, I’m laser-focused and probably saying “Ooohh.” https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620684462015-LQ5MD21KTAJQDXCFDBJO/drums_live.jpg Gallery I started piano in the 3rd grade and played percussion for my junior high and high school years. In high school I picked up guitar and bass and I was an influential member of many jazz, rock, funk, and metal bands. Pictured above is me on stage during a Valentine’s Day performance with my sister’s dance troupe circa 2014. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620686940158-FAFJMJDE6WZ33JKRL8N1/IMG_6915.jpeg Gallery I think this was in East Burke, VT on Burke Mountain. Home of the Kingdom Trails network, East Burke is always a nice getaway from the city life. The fresh air and friendly folks remind me of home. https://www.russellstanbery.com/home daily 1.0 2025-07-28 https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/6d7d6694-429d-475a-8957-2902ddea0863/tempImageexDFl7.jpg Home https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620683326973-6J6PC49IHSVRSKLF3N5D/IMG_9489.jpeg Home I can say with certainty that solving challenging problems is my lifelong passion. The process of discovering an issue, making a plan, executing that plan, and then evaluating the result is a satisfying evolution, even when it doesn’t pan out. I often try several designs, several plans before I land on the right one and though it can be frustrating, I enjoy the learning that goes along with failing. Over the years I’ve learned valuable skills including how to change car brakes, how to overhaul mountain bike suspension, and how to write computer programs to control sensors. I’m always looking for the skills to learn or the next challenge to sink my teeth into. For more information on my projects, contact me or take a look at my portfolio on this site! https://www.russellstanbery.com/contact daily 0.75 2021-05-14 https://www.russellstanbery.com/portfolio daily 0.75 2026-02-11 https://www.russellstanbery.com/portfolio/relief-valve-test-fixture monthly 0.5 2021-05-11 https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1621016541629-QB50HEW4F9GLE7HLWOFE/IMG_0423.JPG Portfolio - Relief Valve Test Fixture The brass relief valve mounted in the test fixture. A three-way valve controls the direction of gas flow. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1621016603617-7V4UNOEMHZ0A38Q5AWL4/IMG_8262.jpeg Portfolio - Relief Valve Test Fixture A photo of the Gas Control Panel (GCP) test fixture with the relief valve test fixture attached. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1621020379233-D12T2OAF7P9TTIWGMXSJ/IMG_0428.jpg Portfolio - Relief Valve Test Fixture A look at the adjustment nut of the relief valve (left) and the adjustment fixture (right). I designed and 3d printed the custom fixture that grabs the nut and the hex pattern of the valve to allow an operator to change the set point. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1621020578894-PLIIXCG15F1RY8VEW07K/IMG_0424.JPG Portfolio - Relief Valve Test Fixture - Make it stand out Changing the set point of the relief valve in the adjustment fixture. https://www.russellstanbery.com/portfolio/project-six-pm2p5 monthly 0.5 2021-04-07 https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1619747314436-FMK2292G132Y7D2QYNSE/IMG_6107.JPG Portfolio - 3D Printed Metal Sign https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1619747484699-VJ7ZYOG406K5I7SX9TG6/IMG_5864.JPG Portfolio - 3D Printed Metal Sign The parts hot off of the 3d printer. The layout is already looking good! https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1621020878738-4BWN3BMNOGRYHRI7THSR/IMG_5892.JPG Portfolio - 3D Printed Metal Sign - Make it stand out Reaming out the holes for dowel pins. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1621021018030-714SLSCIOY7BU0H6NJGC/IMG_5901.JPG Portfolio - 3D Printed Metal Sign - Make it stand out Some small TIG weld joints held the stainless pieces together. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1619747739383-ST8IL8PQAR2PRUPCFYO8/IMG_5872.JPG Portfolio - 3D Printed Metal Sign Ready to go into the sintering oven. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1621020969009-TSMW083J3YCD3PKWPJDP/IMG_5890.JPG Portfolio - 3D Printed Metal Sign - Make it stand out Checking the layout before welding. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1621021121570-ASO5D2HZXU47TQBP744J/IMG_5899.JPG Portfolio - 3D Printed Metal Sign - Make it stand out All welded up, ready to buff out the heat marks. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1621021179471-A1SMGTYQ57F07OK3FWLV/IMG_6108.JPG Portfolio - 3D Printed Metal Sign - Make it stand out The final product came out great! https://www.russellstanbery.com/portfolio/others monthly 0.5 2026-01-24 https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/f457a19d-a3c5-47f7-90b9-42926ec222e9/Screenshot+2025-07-28+171922.png Portfolio - Some Other Projects! - Make it stand out This is a hardtail mountain bike frame that I’ve designed for aggressive trail riding. It features carbon tubing with 3d-printed lugs (3d printed steel or carbon fiber) and a mullet wheel set up (29” front wheel, 27.5” rear wheel). Right now it’s in the design phase and I’ve 3d printed some of the lugs as mock-ups. Hoping to do a full build of this soon and get out on the trails! https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620748801306-U28PODN5RFF9JHSG6ODN/IMG_9679.jpeg Portfolio - Some Other Projects! Made a simple wheel truing stand for bikes. So simple but effective. Future design(s) will incorporate two-sided truing abilities and maybe a built-in dishing tool. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620750164251-UWS30N7N1OBSBZGR3TOM/IMG_0326.jpeg Portfolio - Some Other Projects! Here’s one example of a calibration stand that I designed and built. This fixture helps make operations, testing, and manufacturing more efficient. The fixture is made of aluminum, so its lightweight but sturdy. The threaded mounting holes are helicoiled for longer lasting threads and the dowel pins help locate the components to be calibrated. I designed and 3d printed the tool-holding blocks to make using this calibration stand a breeze. The next step for this project is to write some Python scripts to aid in the calibration/validation measurements. After its deployment to the production line, this fixture will be an important tool to ensure quick and easy calibration, saving valuable time and engineering resources. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620750436938-EFV37L6IVQ4IFPRWXF1K/IMG_6645.jpeg Portfolio - Some Other Projects! https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620750464159-L6PIUDAHLIT6SW2WWTCF/IMG_6661.jpeg Portfolio - Some Other Projects! https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620749496060-732LRMIVMI1R5OFNZCTA/IMG_2071.jpeg Portfolio - Some Other Projects! 14” Meade telescope at the University of Montana campus observatory. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620751343741-URQQ571RGM8MRF1QSYC4/IMG_2096.jpeg Portfolio - Some Other Projects! A wooden tray I made for someone’s Christmas gift. Nothing too special; I used recycled everything, applied a nice stain, and used my original design. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1620751555851-KWI9BWUR8JWG36XU3GEC/IMG_1485.jpeg Portfolio - Some Other Projects! I made a fun little wind chime/mobile art piece for my Mother using recycled wood, cut wine bottles, and an old cymbal. This piece was super fun to design and make. Cutting wine bottles uniformly can be tough! This mobile catches the wind and you can hear peaceful gong-like sounds from the cymbal, topped with the clinking of the wine glass. https://www.russellstanbery.com/portfolio/fiber-alt monthly 0.5 2021-04-29 https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/5e9b6c6f-44f2-459e-801c-4391d4d44319/IMG_9777.jpeg Portfolio - Fiber Cutter Accelerated Lifetime Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/d19b3e3e-d4fd-40d0-974a-63c29a6c8d63/IMG_9778.jpeg Portfolio - Fiber Cutter Accelerated Lifetime Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/ff375883-803b-44de-b4b9-3f21d1e8dcec/IMG_9874.jpeg Portfolio - Fiber Cutter Accelerated Lifetime Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/80b5cc6f-257b-44d6-bbbc-87a7ee52b9aa/IMG_0062.jpeg Portfolio - Fiber Cutter Accelerated Lifetime Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/f1c4826c-ca66-43e9-a80e-c477fa30deee/IMG_0107.jpeg Portfolio - Fiber Cutter Accelerated Lifetime Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/ad7ab606-60be-4c48-98e3-4c677c33689f/IMG_0063.jpeg Portfolio - Fiber Cutter Accelerated Lifetime Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/6b84fcec-726f-4c54-b594-3ba1349357f1/IMG_0061.jpeg Portfolio - Fiber Cutter Accelerated Lifetime Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/d65a33e1-4b2d-421c-b811-b1f8ce66e9a7/IMG_0237.jpeg Portfolio - Fiber Cutter Accelerated Lifetime Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1616293740866-V7323YT7D19TAJW3R9KP/IMG_0237.jpeg Portfolio - Fiber Cutter Accelerated Lifetime Fixture The basic premise of this fixture was to test the lifetime of our new carbon fiber cutter module to see how long the design would last in the 3D printer and give us important insight in the failures we could see in customer’s machines. Regular operation was for carbon fiber (mounted on spools at the back of the fixture) to be pulled a certain length by an extruder motor and then cut. This process would repeat itself until there was a cutter failure or material jam. The design had several variables to consider. First, the testing environment had to mimic the actual conditions in the printer and be able to maintain at least 80 degrees Celsius while cutting fiber continuously. We also needed somewhere for the cut fiber to go, as carbon fiber falling onto electric heater coils could result in a fire or an electrical short. An added perk was to make the testing fixture interchangeable, so future engineers could replace the modules with other parts to test. I came up with the design, sketched it all in Solidworks, and used leftover printer parts to get the right electronics I needed. I machined custom hardware, heavily modified an off-the-shelf laboratory oven, and came up with safe methods to mount electronics and handle waste fiber. I used rivet nuts and bolts for fasteners so the design was robust, but easily customizable. All the electronics are mounted on standoffs, safe from the heated chamber and all cables were custom-made and routed in an organized fashion. This fixture is still cutting to this day with no failures in the cutter modules, even after hundreds of thousands of cuts each. https://www.russellstanbery.com/portfolio/gcp-test-fixture monthly 0.5 2021-04-29 https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/817aae90-8efb-41a5-b5d8-25e722ecc5ff/PXL_20201215_203938082.jpg Portfolio - Gas Control Panel Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/a7dc28f7-a633-49c4-9fff-b143916aa03e/PXL_20201215_203924059.jpg Portfolio - Gas Control Panel Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/23218ada-2a81-46c6-80b9-b9a20e280f7a/PXL_20201215_203944360.jpg Portfolio - Gas Control Panel Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/4f5559c9-1b45-46ca-97db-db30dbcf3061/PXL_20201215_203952788.jpg Portfolio - Gas Control Panel Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/a99566a2-0640-4eb7-8af5-fbc47ac0d37f/PXL_20201215_203927534.jpg Portfolio - Gas Control Panel Fixture https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1616035296339-MVA6CXTKLIPIEFHID84J/PXL_20201215_203932509.jpg Portfolio - Gas Control Panel Fixture - I created an easy-to-use fixture for validating pneumatic assemblies before they go into production machines. Markforged furnaces use gas mixtures to create inert environments for metal sintering. The control, flow, and pressure of these gases must be controlled using a Gas Control Panel (GCP). We needed a robust GCP test fixture that the manufacturing team could use for validating the GCP assemblies before these assemblies go into customer’s machines. Before this fixture existed, we literally had 2-3 engineers that knew how to validate GCPs and they had to hand courier these assemblies from our manufacturing facility to our main office to do so. I familiarized myself with the testing methodology, the tools and components required, and went to work making a fixture so we could save valuable engineering time and money by having technicians at our manufacturer validate GCPs quickly. This fixture filled the GCP with gas and tested the solenoids, pressure sensors, and flowmeters. The test setup required two regulators, a digital flowmeter, multiple ball valves, a safety relief valve, and some electronics. I organized all the parts using an off-the-shelf washdown enclosure. I used Solidworks to map out where and how to mount all the components, and designed and built mounting brackets to hold everything in place securely. In my design, I took into account the fact that this fixture would be used in a production setting at our manufacturer. I mounted all the components such that they were easy to use and routed cables and tubing in a neat, safe, and clean fashion. Technicians and engineers loved the fixture for its elegant simplicity as it saved time on our production line - in turn saving the company money. https://www.russellstanbery.com/portfolio/siab monthly 0.5 2021-04-30 https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1616035041928-67NQYOEA9UKVNJO5P77H/IMG_7543.jpg Portfolio - Furnace In A Box https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/4bac8526-1ab0-4e2b-a76d-61a78beaae22/IMG_7279.jpg Portfolio - Furnace In A Box https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/541e5fbb-632f-4980-9542-bc8d3917ad65/IMG_7542.jpeg Portfolio - Furnace In A Box https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/9d5afa2b-7307-40db-afd5-43f1eca88b3e/unnamed+%281%29.jpg Portfolio - Furnace In A Box https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/ce137c34-3743-4488-aba2-56e71ba82255/6797d560-6c71-4542-b2e6-5e374034bd43.jpg Portfolio - Furnace In A Box https://www.russellstanbery.com/portfolio/log-press-machine monthly 0.5 2026-02-11 https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/8a12d97d-2855-469e-9292-5c6e24e78b86/Screenshot+2026-01-05+at+5.23.01%E2%80%AFPM.png Portfolio - Log Press Machine Simple CAD assembly to start https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/5e383bb3-e748-412d-8efb-744b82a108b7/9E540D6C-48E2-4583-879A-A0170B323684_1_105_c.jpeg Portfolio - Log Press Machine Milling the Aluminum plunger pieces https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/231b6144-8f1b-48df-a6f0-16910e2af7d4/94C0A5A9-D72C-404B-BF2A-0745AD353F84_1_105_c.jpeg Portfolio - Log Press Machine Added holes in everything for water displacement https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/c0e44859-153f-4832-8cd1-3c84c9db69f0/5DE79A7B-3CEF-4C4A-9E45-925CB2727F12_1_105_c.jpeg Portfolio - Log Press Machine Coming along nicely! https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/a7d1041c-a507-430f-a119-4900419f210b/36895563-DEF6-43CE-97C4-5917DF51E1C0_1_105_c.jpeg https://www.russellstanbery.com/portfolio/s2-gauge monthly 0.5 2021-04-30 https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1619748598545-DG3QR8JIYSBYOHNHJ8ZA/IMG_6604.JPG Portfolio - Furnace Core Inspection Gauge - I delivered a key tool to ensure seamless production. Our furnaces at Markforged are made of insulated cores, similar to typical laboratory furnaces. The photo to the left shows a sideview of a Sinter-2 furnace without the heating retort, where the white core is visible. This white inner tube is what our production team had to measure quickly and effectively. The core is the largest part of the furnace. It’s a 3 ft long tube of 10.35” inner diameter, tightly toleranced to +/- 1% and made of a ceramic-like material. The material is very brittle and dangerous if inhaled, so consecutive measurements had to be easy, safe to perform, and cause minimal damage to the core. The required tool needed to measure the inner diameter of the core and the length simultaneously. So I designed a large gauge pin/go-nogo gauge. Obviously, this gauge needed to be lightweight, so I started with two 3d printed plastic rings connected with aluminum rods. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1619749649765-2JYV9XMQ2JJVO8LFMQ4G/Screen+Shot+2021-03-17+at+9.59.56+PM.png Portfolio - Furnace Core Inspection Gauge I found the 3d printed prototype gauge was out of spec and was actually slightly elliptical in shape - either due to issues in materials or the printing process itself. I tested these hypotheses by printing several thinner rings at different orientations in the printer. I measured the test parts immediately after printing and took another measurement after a few days - to account for any atmospheric moisture that might have gotten absorbed into the nylon-based printed material. After concluding the 3d printed versions were just not accurate enough at that large size, I redesigned the gauge to accept machined Delrin end caps - which would be much more precise. I assisted in the machining process, inspecting parts and troubleshooting issues along the way with our machinist. I assembled the final version and sent the gauge to our production vendor with an inspection report. With the gauge in hand, the manufacturing team was able to keep their line running and avoid significant delays in production. This led to production uptime and many happy customers. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1619749951007-EBRXEBTPXTN9KCFNXF62/IMG_7155.JPG Portfolio - Furnace Core Inspection Gauge Inspecting the gauge outer diameter. Multiple measuring points were necessary to ensure it was in-spec. https://images.squarespace-cdn.com/content/v1/604c3def000a5a4938618b45/1619750118226-I6X8F10983XK04OOGKDL/IMG_7152.JPG Portfolio - Furnace Core Inspection Gauge Checking for ellipticity.