This project investigated water reversion and intrusion within an outboard engine's exhaust and muffler system. The work involved developing a test plan, instrumenting a boat for on-water testing, collecting engine and system data, and analyzing the results to better understand exhaust behavior and…

This project focused on designing and optimizing a lightweight drone frame while meeting structural, loading, and manufacturing requirements. I used SolidWorks CAD and FEA to evaluate the design under two loading scenarios, then used topology optimization, design studies, and MATLAB Response Surface…

During my Mechanical Development internship at Mercury Marine, I supported an ongoing investigation into increasing lubrication oil consumption. My role involved structured problem-solving, engine inspections and teardown work, test data analysis, root cause analysis, and research into potential…

Mercury Marine was experiencing invalid and delayed oil sample analysis results, limiting the ability to detect engine failures before corrective action could be taken and creating significant yearly costs. This project focused on evaluating options for bringing used oil analysis capabilities…

This project evaluated the performance of a flush system for a new engine DVP. I developed a test plan, instrumented the engine, and performed testing to collect data on system performance. The results were recorded using an Edaq data acquisition system and analyzed to determine the effectiveness of…

During the Gun Drill operation of Prop Shafts at Mercury Marine, improper chip formation caused stringers to accumulate around the drill, resulting in chip buildup and coolant spillage. I redesigned the bore geometry to allow the gun drill to engage properly, improving chip evacuation and reducing…

I investigated the feasibility of integrating Garrett's 48V electric compressor into our Polaris ProStar S4-powered Clean Snowmobile. The project involved analyzing real engine test data, calculating boosted mass airflow and pressure ratio, evaluating compressor compatibility across the engine…

As part of the Badger Clean Snowmobile Team's powertrain development efforts, I led the implementation of a passive prechamber ignition system to improve combustion performance and explore opportunities for improved engine efficiency and emissions. After initial prototype testing identified…

A friend had an older chainsaw that had previously been used during the construction of a cabin but had stopped running. I took on the project as an opportunity to diagnose the mechanical issues, disassemble and rebuild the engine, and restore the chainsaw to operating condition. The project allowed…

Spline gauges used for driveshaft inspection at Mercury Marine were prone to sticking on spline profiles, allowing carbon buildup inside the gauges and contributing to approximately 150 minutes of lost production time per month. The goal of this project was to design a custom case that accurately…

Broaching tools stored at Mercury Marine had an inadequate storage and transportation system creating safety hazards, congested work environments, and inefficiencies in the plant. The goal of this project was to design and manufacture a simple storage system to reduce congestion and intense manual…

The rust preventative applied to components awaiting directional shot peening in Mercury Marine heat treat is not being adequately removed, causing contamination within the shot peening equipment and diminishing the effectiveness of the shot peening process. The objective of the project was to…

I converted my dirt bike into a more street-oriented supermoto bike while using the project as an opportunity to develop my understanding of motorcycle systems and hands-on mechanical skills. The project involved rebuilding braking components, servicing the rear suspension, replacing drivetrain…

As President of the Badger Clean Snowmobile Team, I lead the overall direction and operation of a student engineering organization focused on the design, development, and competition of a low-emissions snowmobile. My role involves coordinating projects and team operations, supporting technical…