In a remarkable display of ingenuity, a sophomore from Lake Mary High School has significantly reduced costs for Seminole County by fashioning a 3D-printed component for ballot printers. This innovative solution was devised for the Supervisor of Elections Office, which manages these essential machines.

Amy Pennock, the Seminole County Supervisor of Elections, explained that the printers rely on a small plastic piece crucial for keeping the ballot paper aligned and preventing jams. When this part breaks, the vendor typically requires the entire tray to be replaced, a process that costs $125 per unit.

Given that there are approximately 150 such printers in use, the expenses for replacing these trays would have exceeded $18,000, Pennock noted.

Instead of incurring these hefty costs, the elections office sought assistance from Lake Mary High School’s advanced manufacturing program.

Enter Ethan Sigal, a resourceful sophomore, who carefully examined the broken piece, took precise measurements, and successfully crafted a new one with a 3D printer.

“I spent about a period or two just measuring it,” Sigal mentioned, highlighting the precision and dedication involved in his project.

He said the work required precision down to hundredths of an inch.

“We actually have to be very precise,” Sigal said.

His teacher, Christopher Endress, said the program gives students hands-on experience turning digital designs into physical objects.

“We do all sorts of CAD work,” Endress said. “And then how to convert that into physical 3D models.”

Pennock said the student-made part worked and cut the cost dramatically.

“Those would have been over 18 thousand dollars,” Pennock said. “Now it’s 15 dollars per part, and the money goes into a school program.”

For Sigal, the project was about more than just saving money.

“It just feels amazing honestly,” he said. “Knowing I made an impact.”

Pennock said she hopes this kind of partnership with local students continues.

Sigal told News 6 he is interested in aerospace engineering or architecture after high school.