Mechanical Engineer II at Stored Energy Systems (SENS)

Mechanical project lead on the development of a new lithium-based battery pack for high-current applications. Created a fixture for 36 battery cells using plastic injection molding and sheet metal construction. Selected and verified a laser welding machine, hot plate welder, leak tester and AI vision system to produce 100+ battery packs per day. Worked cross-functionally with manufacturing to spec and install a $1.5M manufacturing line for this new product. Calculated resistive heat generation through the entire system to inform thermal management decisions. Designed systems to meet UL 1973, UL 840, and UL 508A. Optimized and automated processes for creating customer-facing drawings of large back-up power distribution cabinets. Used templates and configurable assemblies within SolidWorks to decrease development time from 2 weeks to 4 hours.

Mechanical Project Lead at OnLogic Inc

Mechanical project lead on the development of two flagship industrial edge PCs, executing three phases of successful design and validation testing. Analyzed quotes and negotiated with international suppliers. Optimized the mechanical tooling strategy of a design package to save $31,000 in tooling costs during development. Streamlined existing designs for optimized manufacturing and assembly, including 17 products across three unique product lines. Championed cost-down initiatives with global manufacturers to save 5% on manufacturing cost of a flagship product. Principal designer for a new VESA-style PC mounting bracket, allowing customers to simulate an 'All-in-One' integrated style PC with a more cost-effective system. Adhered to electrical immunity requirements, EMC compliance, and UL safety standards. Partnered with electrical engineers to develop a new 12-28V power input card to power an expansion options for a consumer PC.