Project Guide
Every major project in one place. Read the short summaries, then open whichever case study is most relevant to what you want to see.
I redesigned a production mold after fully disassembling and rebuilding the existing tooling to understand how it worked and where it failed. The new dual-cavity design doubled production in the same floor space, used hinged faces and quick-release clamps, and grew into a major cross-functional tooling program.
Open full case study →I replaced a slow ten-bolt demolding process with a retained swing-bolt system that kept the mold aligned and eliminated loose hardware. The redesign cut demolding time from about 12 minutes to 2 minutes, an 83 percent reduction, while improving safety and repeatability.
Open full case study →When new dimensional requirements arrived before permanent tooling was ready, I designed, cut, machined, assembled, and implemented a temporary mold extension system in two weeks. The solution avoided a four-week coating delay and helped protect production with roughly $40,000 per day at risk.
Open full case study →I developed a complete daily testing system built around six production test molds, coordinated machining and coating vendors, managed procurement, assembled the molds, and mounted them to a rolling station. I also prepared three additional molds for future production ramp-up.
Open full case study →A critical customer repair required a wire-saw cut that had previously filled the room with airborne dust. I designed and fabricated a small PVC and flame-retardant containment enclosure around the workpiece instead of the entire machine, allowing the repair to proceed safely and quickly.
Open full case study →My team built an autonomous warehouse robot that followed routes, sensed storage locations, and moved crates. I focused on the mechanical design and rack-and-pinion scissor lift, using Fusion 360, 3D printing, Arduino hardware, and repeated prototype testing to improve reliability.
Open full case study →I designed and 3D printed calisthenics parallettes that I use regularly, then validated the structure with ANSYS. I also redesigned the supports to reduce filament and print time by about 50 percent, fit twice as many parts on the print bed, and cut estimated manufacturing cost by 39.8 percent.
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