Physical systems taken from concept sketches to fabricated, tested hardware.
3D-printed fixture grids enforcing Work Coordinate Systems (WCS) for automated Micro-Vu optical inspection — hands-on design for inspection, GD&T application, and high-volume fixture design built around positioning geometry.
Lead mechanical engineer on a vision-driven arcade cabinet — reworked rapid prototyping to cut material cost 33% and build time 50%, engineered winching gates, axles, and rack-and-pinion disposal mechanisms, and applied GD&T fits and clearances for 95%+ reliability.
FEA-driven topology optimization to reduce vehicle component mass while maintaining factor of safety, coupled with manual lathe/mill machining to ±0.005" tolerances — from structural CAD simulation to CAM G-code and physical parts.