Design & Deployment of a Remote Aerosol Research Facility

Mechanical design • Field instrumentation • Systems integration

Remote aerosol research facility and inlet system

What I owned

  • Concept → CAD → fabrication-ready drawings
  • Design for field constraints (wind, snow, access, maintenance)
  • Thermal strategy (heat tracing, insulation, condensation control)
  • Integration of inlet + tubing + instruments within the container lab
  • On-site installation, commissioning, and troubleshooting

Outcomes

  • Deployed a heated aerosol inlet system at a remote mountain site
  • Integrated multiple instruments into a container-based lab layout
  • Produced months of continuous, usable data under winter conditions
  • Created documentation supporting repeat deployment and servicing

Tools & skills

SolidWorks / Fusion 360Fabrication drawingsAluminum & steel fabricationHeat tracing & insulationFlow control / sampling linesField commissioning

The core challenge was building a sampling system that behaves like a lab instrument while living outdoors: freeze–thaw cycles, wind exposure, limited access for repairs, and strict requirements on sampling integrity.

I focused on design choices that would survive real field conditions and still be maintainable: robust mounting, sensible cable/tube routing, serviceable subassemblies, and clear documentation. The comparisons below show “design intent” versus the as-built hardware installed in the container lab and at the site.

Design → Build comparisons

A few snapshots that highlight the path from CAD and layout planning to fabricated components and installed hardware.

Seal assembly

Condensation control and serviceability at the inlet interface

Seal assembly - Design (CAD)
Design (CAD)
Seal assembly - Built (installed)
Built (installed)

Designed the seal interface to prevent moisture ingress and to be easy to service in the field (glove-friendly fasteners, accessible mating surfaces, and clear assembly order).

Inlet inside the container

Routing, accessibility, and minimizing sampling artifacts

Inlet inside the container - Design (layout / CAD)
Design (layout / CAD)
Inlet inside the container - Built (as-installed)
Built (as-installed)

Planned routing and mounting inside the container to keep lines short, reduce sharp bends, and preserve access for maintenance while keeping heaters and insulation organized.

Lab equipment layout

Instrument placement, mounting, and cable/line management

Lab equipment layout - Design (floorplan / layout)
Design (floorplan / layout)
Lab equipment layout - Built (as-built)
Built (as-built)

Converted an instrument wish-list into a workable layout: mounting strategy, service clearances, airflow considerations, and practical cable/line routing for long-term reliability.

Additional photos

Inlet assembly
Container lab interior
Field deployment

References & context

This system supported atmospheric field campaigns focused on aerosols and cloud microphysics in the Wasatch Mountains and contributed to ongoing research into dust, ice-nucleating particles, and regional air quality.