At Allen Bradley, I designed a product line that was comprised of nine optical sensors. The product had to be designed to work in harsh environments such as bottling plants and car washes. It had to withstand heat and be waterproof. During installation, there needed to be access to set the calibration. From a design perspective, there were common parts like the rectangular housing, the shape of the circuit board, the back cover, and the external shape of the front snout. I used the Pro/Engineer configuration capability to manage the custom features such as the internal geometry of the snouts, the plastic lenses, and the variations of the PCBs. I used rapid prototyping techniques to focus on the challenging aspects of the design such as sealing the wire entry area and ultrasonic welding of the snout to the housing. I created all the detailed and assembly drawings for the all the parts which included GD&T tolerances. The project was completed in 8 months.