Work Experience

Mechanical Design Engineer

Sherpa Design | Portland, OR | Oct 2021 – Present

• Rapidly generate mechanical design solutions across various subsystems (camera/sensor retention/location, extensive R/FPC design, IP seals, complex sheet metal parts and injection molded enclosures) in a tightly ID bound package that requires environmental protection and deft thermal management

• Efficiently communicate cross functionally to highlight design tradeoffs and streamline decision making

• Fully own critical subsystems from design through prototyping and production

• Collaborate extensively with manufacturing engineers (internal and external) to optimize the production of complex and delicate parts

• Manage drawing release packages through Teamcenter for prototype and production builds

• Team subject matter expert for NX advanced surfacing + dealing with stubborn ID surfaces

R&D Engineer, Hardware

Hawthorne Gardening Company | Portland, OR | Oct 2020 – Oct 2021

• Sole mechanical engineer responsible for exploratory work, new product development, and sustaining engineering 

• Established processes, best practices, and workflows for nascent R&D organization 

• Led cross-functional team, including internal stakeholders and outside contractors, through the implementation of critical software infrastructure for engineering collaboration (Solidworks PDM) 

• Worked directly with internal manufacturing and contract manufacturer to produce parts

• Owned multiple product launches per year with accelerated timelines of 4 - 9 months from product requirement delivery to product launch 

• Designed grow trays, benches, air delivery systems, and other components of advanced hydroponic systems requiring precise flow control and environmental sealing

Senior Mechanical Engineer

Digital Lumens | Boston, MA | Nov 2018 – Oct 2020

• Lead mechanical engineer developing IoT enabled LED light fixtures for industrial use 

• Managed multiple projects simultaneously using JIRA and Smartsheets

• Designed IP rated enclosures for sensitive and high-voltage electronics, including custom sealing solutions and environmental validation testing

• Directed a team of interns, managing day-to-day tasks and development, as well as higher level learning goals and constructive feedback 

• Frequently interfaced with contract manufacturers (in China and Mexico) throughout the R&D and manufacturing process, including the creation of production assembly guides and in-person production line development 

• Directed company-wide rollout of Solidworks PDM for CAD model revision control and multi-user workflow

R&D Engineer II, New Product Development

Endoscopy, Boston Scientific | Marlborough, MA | Sep 2015 – Nov 2018

• Part of a core technical team bringing novel medical devices to market

• Key design team member for modeling, drawing, and rapid prototyping utilizing SolidWorks 

• Managed model and drawing packages for two devices from concept through production

• Conducted environmental and biocompatibility testing using instrumentation including strain gauges, environmental chambers, thermocouples, and load cells

• Created specifications and associated test methods to verify product performance using statistical analysis with Minitab and Design of Experiments with Design-Expert 

• Responsible for root cause analysis of device failures using Ishikawa Diagrams and other tools 

• Produced technical reports to document design decisions and communicate design intention 

• Worked extensively with suppliers (internal and external) to produce parts that met spec on time and under budget 

• Worked directly with doctors and other medical professionals to validate and optimize products

Project Engineer

Ensign-Bickford Aerospace & Defense | Simsbury, CT | June 2014 – Sep 2015

• Managed validation testing on up to four internal and external projects at a time (environmental, shock/drop, vibration, functional testing)

• Worked closely with manufacturing to identify and diagnose issues and keep parts moving for demanding clients (SpaceX, Blue Origin, ULA)

• Prepared written reports and delivered presentations to internal management and customers 

• Hosted customers to answer questions during test witnessing and source inspection 

TECHNICAL SKILLS

CAD/Design Software: 4 years NX+TC (30+ hrs a week, complex surfacing), 10+ years SolidWorks experience w/ PDM (CSWP), Arena

Analysis: Design of Experiments, statistical analysis (Minitab), structural FEA fundamentals

Manufacturing (Production): Thixomolding, CNC mill/lathe, plastic injection molding (including overmolding), thermoforming, sheet metal bending and stamping, deep draw sheet metal parts, cast metal parts, foam-in-place seals, and compression molding

Hands-on prototyping: 3D printing, laser cutter, CNC mill, sheet metal cutting and bending

Design for harsh environments: IP rated enclosures (65, 66), sealed systems

Testing and Instrumentation: Environmental chambers, IP testing, Instron (universal testing machine, including test and fixture design and validation for device FDA approval), vibe testing, shock/drop, thermocouples, strain gauges, load cells, relays

EDUCATION

Worcester Polytechnic Institute (WPI)

Bachelor of Science in Mechanical Engineering
Concentration in Mechanical Design | May 2014 | Worcester, MA