• IT USA (Imdex): PCB test fixtureBench-tested prototypeCut estimated PCB check time from 8 min to 1.5 min with a fixture that probes 12 test points in one clamp press.
• Atlas Copco: sensor calibration fixtureIn developmentWrote the C++ readout, Python sine fit, and 9-source uncertainty budget for accelerometer calibration of rotor position sensors. Shake-table test next.ME 4460
• Lightweight bracket for metal 3D printingSimulationCut modeled mass 35.6% on a 316L bracket for metal 3D printing; modeled deflection against six wall-restraint cases.IME 4432
• Terumo Neuro: pilot-line fixturesDeployedRaised razor blade life from 3 cuts to 15 and cut tack-weld cleaning time 89% with 5+ pilot-line fixtures.
• FIRST Robotics: FTC and FRC robot designCompetedDesigned and machined FTC 15281's robot: a 4-DOF arm and a latch that raised and lowered the 30 lb robot. Later FTC 4143, FTC 8176, and FRC 6831.

Mechanical design

• SafeBase.AI sensor housingDesigned, printed, and assembled a hard-hat sensor housing in about two weeks; team placed 3rd and won $10,000.
• PolyUAS gimbal mountCut camera gimbal mount mass 45% from Mk1 to Mk4; printed, with deflection modeled in Abaqus.

Manufacturing

• Trust Automation: Kanban and 5SBuilt a two-bin Kanban for 25+ Creform part numbers; redlined 7 work instructions; reorganized storage to 5S.
• Welding and fabricationDesigned, welded, and sold furniture and fireplace log sets for up to $700.

Research

• Scoliosis brace manufacturing and modelingPython pipeline from a raw handheld scan to a closed torso model, and an Ansys spine model for brace loads.

Classwork

• Rocket booster attitude controlTuned a PD controller that settles in 3.15 s with no overshoot, in simulation.ME 418
• Two-stage gearbox designGear sizing, shaft fatigue design, bearing selection, and manufacturing drawings.ME 329
• PVC racing kart frame analysisBeam FEA showed the frame was overbuilt; downsized from 1.5 in to 1 in pipe. Built and ridden.ME 328
• 747 wing and Saturn V modal analysisFEA modes checked by hand on a beam and against a shaker test of a wing model.ME 318
• Differential-drive robot modelNonlinear state-space model of a two-wheeled robot, linearized and simulated.ME 322
• Solid modeling and drawingsVise assembly, fixture drawing package with GD&T, and mechanism motion studies.ME 130, ME 251