Case Studies

Product Consolidation

Design Engineering:

  • Consolidated two, similar, pipe seals into a single dual-compatible product

  • Conducted material flow and stress analysis to validate design and confirm requirements

  • Bidirectional design minimizes field installation errors and reduces time to install

Prototype to Production:

  • Worked with partners to develop a prototype mold and validate manufacturability

  • Selected material for manufacturability and component life cycle requirements

  • Successfully consolidated multiple product line to a single, bidirectional seal

Rapid Replacement:

  • Using rubber 3D printing, rapid prototypes were created for testing and verification

  • Created transparent outer pipes to analyze seal material flow when pressurized

  • Seal cross section iterated and updated until desired seal pressure was achieved

Fluid Roulette Wheel

Engineering:

  • Designed a fully-integrated mechanical fluid system to dispense liquids into a rotating array of shot glasses

  • Developed full detailed CAD assembly - optimizing manufacturability and service accessibility

  • Engineered and integrated pump selection, flow control, controls, and Bluetooth user interface

Iteration & Continuous Improvement:

  • Iterated geometry and materials for improved performance and sound dampening

  • Optimized mechanical timing, user interface, and reliability through a constant feedback loop

  • Polished the final product and integrated custom electronics for efficiency and space savings

Prototyping:

  • Rapidly produced high-quality prototypes using in-house 3D printing

  • Integrated commercial off the shelf components, electronics and wiring, and controls in house

  • Validated space constraints, wire routing, and assembly procedure -

SpaceX Palletizer Concept Design

Delivered as part of a SpaceX technical evaluation - including a full design review with engineering leadership

Engineering:

  • Designed a high-throughput palletizing system capable of exceeding 900 units/hour while maintaining strict stacking constraints

  • Performed detailed mechanical analysis for critical subsystems, including lift system force, torque, and power requirements

  • Created detailed electrical schematics and I/O mapping for sensors, actuators, and motor control systems

Project Proposal:

  • Developed a complete concept-to-production roadmap, including design, build, testing, and validation phases

  • Defined validation strategy including installation, operational, and performance qualification testing

  • Proposed scalable architecture capable of increasing throughput with minimal subsystem redesign

Process Analysis:

  • Mapped full system workflow from conveyor input to pallet output, identifying key stages and dependencies

  • Performed cycle time analysis to validate throughput targets and identify system bottlenecks

  • Evaluated throughput sensitivity to conveyor speeds and actuator timing to identify performance improvement opportunities