Handheld Hockey: Interactive Hockey Coin Bank

Handheld Hockey: Interactive Hockey Coin Bank

The Manufacturing Processes and Systems course at RPI tasks students with mass-producing 300 physical units of a custom product within a strict 3-month timeline and a $3,650 budget. Serving as the Project Manager for a 13-person multidisciplinary engineering team, I led the design and full-scale…
Siemens NXMastercam (Live-Axis Milling, CNC Toolpaths, & Turning Operations)Altair Inspire Form (Sheet Metal Simulation)Autodesk Moldflow (Injection Molding Simulation)Octopuz (Robotic Simulation)Design for Manufacturability (DFM)Technical Project Management & Supply Chain CoordinationCNC Milling & 4-Axis Turning (Haas VF2SS, Haas ST10Y)Sheet Metal Deep Drawing & Metal FormingPlastic Injection Molding (Arburg Allrounder 221K)Vacuum Forming (Formech 508FS) & Abrasive Waterjet CuttingUniversal Robots (UR10e) & Custom End-Effector DesignRoot-Cause Analysis & Tooling TroubleshootingQuality Control (Go/No-Go Gauges) & Standard Operating Procedures (SOPs)
Canboni: Can Holding Zamboni

Canboni: Can Holding Zamboni

Collaborated as part of a 10-person multidisciplinary engineering team to design and validate the manufacturing processes for a functional model Zamboni that securely stores a 12 oz beverage and features a rubber-band locomotion system. This project was part of a competitive design phase against…
Siemens NX (Component Design & Master Assembly Management)Design for Manufacturability (DFM)Technical Data Packages (TDP)Universal Robots (UR) ProgrammingRobotic End-Effector DesignMastercam (CNC Toolpaths)Altair InspireForm (Metal Forming Simulation)Moldflow (Injection Molding Simulation)Tolerance & Press-Fit CalculationsKinematic & Energy AnalysisPlastic Injection Molding DesignCross-Functional Team CollaborationRapid Prototyping & 3D Printing (TPU/FDM)
Semi-Permeable Fluid Path: 65-Micron Drilling Fixture Development

Semi-Permeable Fluid Path: 65-Micron Drilling Fixture Development

During my R&D Engineering internship at Becton Dickinson (BD), I was tasked with developing a proof-of-concept to determine if the microscopic 65-micron holes required for a semi-permeable fluid path could be reliably drilled in-house. I served as the lead for developing the complete manufacturing…
Multi-Stage Micro-MachiningSolidWorks (Boolean Cavity Modeling & Depth Calculation)SLA 3D Printing (High-Tolerance Fixturing)Proof-of-Concept (POC) Development\Visual Inspection & Quality Validation ProtocolsStandard Operating Procedures (SOPs) & Process Documentation
Led Light Housing Redesign

Led Light Housing Redesign

During my engineering internship at Telemetrics Inc., I led the redesign and in-house manufacturing of a custom LED light housing. The primary objective was to replace the legacy FDM-printed housings with a solution that significantly improved the optical diffusion of the LED strips while…
SolidWorks (CAD Modeling & Internal Routing Design)SLA 3D Printing (Formlabs Form 4)Design for Assembly (DFA) & Design for Manufacturability (DFM)Cost Reduction ($100 per unit) & Manufacturing OptimizationRapid Prototyping & Material SelectionOptical Diffusion & LED PackagingHardware Integration & Reverse Engineering
Rover Hoist

Rover Hoist

Previously, moving the 150lb robotic rovers from the ground to the elevated work platforms required taking two people away from their regular tasks. To solve this, I designed and built a custom mobile hoist to make lifting and moving the rovers a one-person job. I initially designed the structure…
SolidWorks (CAD Modeling & Assembly Design)Structural Frame Fabrication & AssemblyMaterial Handling & Hoist IntegrationWorkflow & Assembly EfficiencyRigging MechanicsHardware Repurposing