Engineering Projects
A selection of mechanical design and CAD engineering projects spanning fluid systems, semiconductor equipment, and clean energy manufacturing.
Fluid Systems Design
High-Purity Gas Delivery System
Designed and validated ultra-high-purity gas delivery manifolds for semiconductor applications. Engineered custom valve assemblies, orbital-welded tubing layouts, and leak-tight sealing solutions meeting SEMI standards. Achieved 99.9999% purity rating at point of use.
- SolidWorks 3D modeling & FEA
- ASME B31.3 process piping compliance
- Helium leak testing to 1×10⁻⁹ atm-cc/sec
Custom Fluid Distribution Skid
Led mechanical design of a modular fluid distribution skid for industrial gas delivery. Integrated regulators, filters, check valves, and pressure transducers into a compact, serviceable assembly. Reduced footprint by 30% compared to previous generation.
- P&ID development & component selection
- Tube bending & welding specifications
- Factory acceptance testing (FAT)
Semiconductor Test Equipment
Wafer Probe Station
Designed precision mechanical assemblies for automated wafer probe stations used in semiconductor testing. Engineered thermal chuck positioning systems with sub-micron repeatability, vibration-isolated granite structures, and EMI-shielded enclosures.
- GD&T to ASME Y14.5
- Thermal FEA (ANSYS)
- Precision motion system integration
Cryogenic Test Fixture
Developed custom cryogenic test fixtures for device characterization at temperatures down to 4K. Designed thermal management systems including multi-stage radiation shields, vacuum chambers, and precision sample positioning stages.
- Vacuum chamber design
- Cryogenic material selection
- CAD: SolidWorks & Inventor
Clean Energy Manufacturing
Fuel Cell Stack Assembly Line
Led NPI manufacturing engineering for solid oxide fuel cell stack production. Designed assembly fixtures, automated alignment tools, and quality inspection stations. Scaled production from prototype to 500+ units/month while maintaining <0.5% defect rate.
- DFM/DFA optimization
- Process validation & SPC
- Production line layout & workflow
Automated Cell Testing Station
Designed automated electrochemical testing stations for fuel cell quality assurance. Integrated gas delivery, electrical probing, thermal control, and data acquisition into a turnkey test system. Reduced per-cell test time by 40%.
- Mechatronic system design
- Sensor integration & calibration
- LabVIEW automation
Rapid Prototyping & Manufacturing
Combining additive manufacturing, CNC machining, and TIG welding to accelerate design cycles from concept to functional prototype — often in days rather than weeks.
Prototype-to-Production Workflow
Developed rapid prototyping pipeline integrating 3D printing (FDM & SLA), CNC machining, and TIG welding to produce functional prototypes directly from CAD models. Cut iteration cycle time from 3 weeks to 3 days for custom fluid system components, enabling faster design validation and client feedback loops.
- 3D Printing: FDM (PLA, ABS, PETG) & SLA resin
- CNC mill & lathe for metal prototyping
- TIG-welded stainless steel assemblies
Custom Fixture & Tooling Design
Designed and fabricated custom assembly fixtures, test tooling, and manufacturing jigs combining machined aluminum/stainless steel components with 3D-printed soft jaws, alignment guides, and ergonomic interfaces. Reduced assembly setup time by 60% through rapid iteration of physical prototypes.
- Hybrid machined + 3D-printed tooling
- TIG-welded structural frames
- Design-for-prototyping methodology
CAD Design Capabilities
- SolidWorks — Advanced 3D modeling, surfacing, weldments, FEA simulation, PDM
- Autodesk Inventor — Parametric design, assemblies, iLogic automation
- GD&T (ASME Y14.5) — Full stack tolerance analysis and detailed production drawings
- ANSYS Workbench — Structural, thermal, and modal FEA
- AutoCAD — 2D layouts, P&ID schematics, facility planning
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