Alexander Ayers Email & Phone Number

New York, Ny, Us

Burlington, Massachusetts, United States

As the Industrial Design Lead at LightForce I work on the product team to create all of the company's non-clinical product offerings. These products range from LightForce's packaging, clinical educational products, physical event assets to customer recognition awards that further marketing engagement. I usher all of these products through the design process stages; discovery of the user, ideation, prototyping, user testing, identifying production methods, sourcing vendors, producing production files, creating guidelines and training documents to internal teams. At the same time I work closely with the marketing team to create launch plans and product release logistics on a lean budget. I collaborate with marketing to understand the LightForce brand and apply it to all the physical items the company is putting out into the market or using to attract new customers and retain old ones. The products are designed to communicate the brand’s custom technology-forward, personalized message.

Burlington, Massachusetts, United States

At LightForce, I manage a team who perform the production, assembly, and fulfillment of 3D printed products, most of which I have designed for our engineering and marketing departments. Working with marketing and Integration, my team produces all the physical education materials that this new medical technology requires to train dental technicians worldwide. We utilize a range of 3D printing technologies to prototype, manufacture, and fulfill these products at our headquarters outside of Boston. I work collaboratively with our process engineering team designing the systems and infrastructure used to manufacture the medical device. Robust custom designed systems are required to post process unique & custom 3D printed medical devices, especially when they are needed to process thousands of parts 7 days per week. I design, prototype and manufacture these with my team at HQ as well as sourcing from domestic and international suppliers. I have led multiple package redesigns from minor adjustments to complete overhauls. I have worked with doctors and dental technicians to understand the bonding process and how our product packaging can affect or enhance that. I have visited patient bondings to learn how the package is manipulated by the user in a real world scenario. With our engineering team, I have explored how our package is utilized by the production team during manufacturing and how different technologies can be incorporated that enhance traceability and quality. I utilize our QMS system to respond to and learn about customer complaints related to packaging to inform design improvements. Beyond all that, we have surveyed offices and worked with our sales reps in the field to collect photos of offices inventory that range from, a couple boxes, to floor to ceiling shelving holding hundreds of patient boxes. I used all these inputs along with production data sets to inform a package design that optimizes the experience of the end user and the manufacturer.

Brooklyn, Ny

- Maintained a comprehensive high-level understanding of how all systems within the clear aligner production process function in order to solve problems and prevent delays- Communicated incoming orders to the production staff- Communicated with enterprise customers the status of orders and any issues with them the will prevent or delay manufacturing- Debugged order/file issues to get them into the production system- Reviewed case plans for compatibility within Brooklab's production system- Used 3shape software to review and export cases into the necessary formats for production

Brooklyn, New York, United States

- Oversaw all aspects of Brooklab's Quality System- Attended FDA hosted meetings & interfaced with FDA auditors and administrators- Implemented the first QMS for the company by working with leadership and the production team- Maintained SOP's, QF's, and WI documents, updating and creating new revisions when necessary- Led weekly meetings reviewing all CAPA's, complaints, & PNR's with the production manager, CEO, & CPO- Communicated with customers any resolutions to complaints received- Helped auditors find necessary information for them to successfully complete system audits- Attended FDA hosted meetings & interfaced with FDA auditors and administrators

Brooklyn, New York

- Working with sales to asses the feasibility of a given project, estimating project quotes, and determining fulfillment timelines for customers- Working directly with customers to collect and understand project requirements- Tracking projects through their entire life-cycle: quote, sale, design, production, quality control, and delivery.- Handling the project sample process, ensuring customer expectations are met with the final delivered product- Communicating with both sales and the customer with project status updates- Giving context to the factory team so they can best prepare parts for the customer needs.- Working with both customer and the fulfillment team to troubleshoot any issues with project fulfillment.- Setting up QC standards and approving parts for customer shipment- Ultimately responsible for completing projects on-time and maintaining our high-level of quality and customer satisfaction- Contributing to the improvement of internal automation tools, software, and factory process

Greater New York City Area

- Operated our factory of 160+ 3D printers- Worked on new and ongoing customer projects from planning to execution- Prepared 3D models for printing- Harvested, cleaned, assembled, finished, packaged and shipped prints- Conducted regular and preventative maintenance on the factory’s 3D printers and other equipment.- Performed work in a safe manner and adhere to safety programs, processes, and procedures- Contributed to the improvement of internal automation tools, software, and factory processes- Worked to continuously guarantee and improve customer satisfaction

Greater New York City Area

-Optimizing workflow of 3D-printed earphones using metrics reports, ultimately reducing production time of Normals from 5 hours to 3.-Ideating future Normal products based on market research, customer demographics, and customer feedback.-Designing future products via drawings, Solidworks models, prototypes, and renderings.-Communicating with factories in China to manufacture and implement new products.-Overseeing factory processes, equipment maintenance, and timely production and delivery of Normals.-Tracking inventory levels of production supplies and reordering when necessary.

Greater New York City Area

-Manufactured, assembled, QAed, packaged and shipped each pair of custom earphones, as many as necessary per day.-Tracked orders of Normals as they were placed by approving or rejecting ear photos.-Worked with engineers to produce Solidworks CAD files for custom earphones and custom cases.-3D-printed models using Stratasys Fortus 250mc printers; maintained printers.-Cleaned models in ultrasonic bath; sanded each pair by hand.-Smoothed (in Stratasys smoothing machine) each pair of Normals to melt the ABS residue left from sanding.-Sprayed each pair of Normals with a soft-touch urethane coating in industrial spray booth.-Used Universal Systems laser cutter to create custom fit cases for the earbuds.-Tested earphone cables and cabinets for premium quality sound using Clio.

Greater New York City Area

-Helped students to safely operate the shop machinery to complete their design projects. -Inventoried, cleaned and maintained shop tools and equipment.

Brooklyn, Ny

Guided 30 pre-college students for 2 months to various tourist destinations around New York City on the subway. Provided a positive experience to the students attempting to peak their interest in attending Pratt Institute. Helped tutor a group of 10 with their design school homework.

Brooklyn, Ny

Bachelor Of Industrial Design (Bid), Industrial And Product Design

Activities and Societies: The Prattler Magazine

Industrial And Product Design