Mechanical Design Engineer at Outbound Lighting

Lead mechanical design and development of 6+ consumer products, including bike lights, mounting systems, and packaging from concept through production. Collaborated with industrial designers to brainstorm concepts, develop sketches, and create detailed part and assembly models using advanced surfacing to translate design intent into manufacturable solutions. Reverse engineered 50+ consumer products to evaluate sealing strategies, USB-C door designs, and interface details, applying insights to current designs. Prototyped concepts using in-house 3D printing to validate form, fit, and function through iterative testing. Produced 100+ detailed 2D manufacturing drawings and performed FEA to verify structural integrity and support design validation. Coordinated with 3+ overseas suppliers on part fabrication, prototype builds, and DFM feedback to meet quality, cost, and schedule targets.

Engineer II, Device Development at Xeris Pharmaceuticals, Inc

Collaborated with product development and manufacturing teams to drive mechanical device innovation, development, and troubleshooting across early development, pipeline, and commercial products. Designed and prototyped 3+ fixtures to support lab development activities, including drug fill, inspection, and testing. Conducted device testing and analysis to support development initiatives and risk management activities.

Design Engineer at Gilero

Led the end-to-end development of 7+ medical devices from conceptualization to market launch, harmonizing product and customer specifications, regulatory compliance, ergonomics, project timelines, and budgets. Served concurrently as Project Manager for 2 projects, managing budgets, schedules, and client communication to ensure successful execution. Drove concept generation and iteration through brainstorming, CAD modeling, and rapid prototyping of functional assemblies and test fixtures, accelerating design maturity. Prepared 200+ component and assembly drawings for injection molding, machining, and thermoforming, supporting smooth transition from prototype to production. Led material selection and vendor collaboration to transition designs to full-scale production, optimizing cost, quality, and performance. Conducted device testing and analyzed results to identify root causes of failures, implementing corrective actions to drive design iteration.