Product Conception, Alpha/Beta Prototyping, Reliability Engineering

I have a lot of experience with mechanism design and the realization of product intent - the connection between what the product designer intends to do and how the product accomplishes its task.  Above are a few examples: A compact rope-driven linear actuator, a high-performance dog clutch intended for an orthotic knee joint, a high-performance portable air compressor, an electric bicycle drive unit, and a speciality bicycle chainring.

In addition to performing product design work, I’m well-versed in quickly conceiving and implementing testing equipment that is capable of assessing product performance and longevity through accelerated life testing. I can also perform failure mode analyses and generate product testing reports.

Patent Writing and Prior Art Research

I've written over two dozen patent applications in the last few years. When appropriate, I can create the written specification and accompanying figures that are necessary for a patent filing, and conduct a thorough analysis of prior art.

For example, this patent that I filed encompasses a novel means of manufacturing a spring component with desirable performance and integration properties, most notably a high volumetric power density and a convenient two-force member load condition.

Modeling and Simulation

I have experience with MATLAB and Solidworks FEA models that grant insight into the subtleties of material forming, and can render vast improvements in functionality and performance metrics.

This MATLAB model that I wrote uses a few inputs and can generate a variety of useful behaviors out of a screw-type mechanism design.  It also supplies the material geometries for input into CAD that are necessary to realize the behavior.

Embedded Software Design

Whether the intention is an automated production line element, a service life testing machine, or a complex electro-mechanical prototype with a dozen sensors and multiple outputs, I have experience designing software that makes automated machinery work reliably while also flagging any fault conditions.

I wrote this script (small sample shown to the right) to perform thousands of hours of testing on linear actuation power systems. The script successfully monitored operational parameters while also watching over a dozen potential fault conditions. Parameters that were monitored include voltage, current, linear and rotational speed, a low-load condition, motor temperature, limit switches, and motor slip, among others.

Electrical Design and Assembly

Using COTS parts, I can design and construct basic electrical systems. I’m familiar with various types of sensors and transducers, analog and digital I/O’s, motor controllers (DC, BLDC, Induction), data loggers, etc.

I designed and built this schematic to perform service life testing for linear actuators.

Vendor Management, Engineering Management

I’ve directed a small team to successfully implement and test a core set of intellectual property. The team consists of two engineers, a part-time technician, a part-time electrical engineer, and a part-time CNC fabricator. I’ve worked with dozens of local and global vendors to source both COTS and custom parts for the project, sending and receiving technical specification documents, discussing detailed points about fabrication processes, and managing relationships for a successful project.