Developed solutions for improving force sensor signal in various industries, such as automotive, industrial and personal electronics. Performed static and thermal FEA using SolidWorks Simulation to capture sensor signal. Designed fixtures to accurately and precisely install small PCB modules onto customer medium for prototypes.

Designed and managed the assembly and start up of a life cycle test station for diaphragm valves. Tests include exposure to acid, corrosives and steam at varying exposure times and temperature. Utilized LabView to control multiple sensors, solenoids and heating elements to evaluate rubber diaphragm life cycle limits.Developed pharmaceutical manual and pneumatic actuators and molded elastomer diaphragms for food and biopharmaceutical industries and markets. Derived requirements and specifications for manufacturing valve bodies, actuators and rubber diaphragms.Engineering liaison with overseas manufacturer to improve component DFM process and developed solutions to improve quality of plastic injection molded and cast stainless steel components. Developed test procedures and documentation for verification and validation of fabricated parts.Using SolidWorks and Flow Simulation, designed and implemented assembly tool to modify existing mixing impellers to improve structural strength and rigidity during operation. Tool allowed for repair components to be accurately installed, welded and maintained concentricity and parallelism of critical pieces during welding and operation.Researched PTFE coatings for elastomer diaphragms and developed injection molded PTFE layered diaphragm to achieve lower cost production and improving cleanablility.

Designed tools and systems to manufacture over 28000 reflective mirror structures and its subsystems for Linear Fresnel Solar Thermal Power Plant (India and Tucson, Arizona).Analyzed designs using SolidWorks Simulation and ANSYS Workbench for frequency analysis, structural and thermal stress. Created detailed parts specifications and drawings. Worked with vendors with quotes, specifications and parts fabrication from single prototypes to small runs of production.Teamed with engineers, vendors, and software developer to design and implement an automated device to measure optical error in milli-radians, utilizing smart motors and belt driven linear actuators, pneumatic cylinders, as well as tilt sensors and proximity sensors.Troubleshot mirrors broken during installation by prototyping manual field mirror shape tool to create curvature in reflective mirror structures. Prototype stage adjustments allowed a production of tools to meet factory optical specifications.Performed root cause analysis of failed drive systems due to high wind loads and oscillating forces. Worked with vendors and controls/electrical engineers to create an upgraded drive system with different slew gear ratios, planetary gear motor and different operating procedures to protect current electrical system.Improved manufacturability of mirror structures through research and testing to validate various adhesives, mechanical fasteners and welding processes. Developed test procedures through designing and assembling prototyped tools to analyze actual performance against modeled performance.

Designed and installed manufacturing tools to coat tubes with a solar selective coating on an in-line continuous chemical plating process. Manufacturing line produced up to 1000 feet of 40 ft long boiler tubes per day.Led the design of a housing for two optical instruments requiring tight location tolerances and automation for periodic calibration. Worked with software engineer to automate process with pneumatics and linear slide assembly.Aided the research and development of Solar Selective coatings to improve performance and lifetime of boiler tubes by designing and specifying parts for lab experimental apparatus. Co-led the development of a laminar flow plating cell to improve coating performance and coating coverage of boiler tubes. Designed nickel plating bath system to rotate samples and improve plating uniformity by using chemically compatible belt and gear system rotated by a smart motor.Developed drip application of Sol-gel with Research and Development Team to protect solar selective coating and to improve coating performance. Worked with scientists and vendors from concept to prototyping to manufacturing readiness.Qualified an in-line paint spraying apparatus for coating paint based Solar Selective coating to work in conjunction with the plated boiler tubes operating at over 400ºC.

Worked under Senior Mechanical Engineer to design equipment for Physical Vapor Deposition or Sputtering onto thin film substrate for energy conservation. Contributed designs to improve change-over time for installing new film substrates and to improve upon previous designs for lower cost and maintenance.Managed the design and installation of mechanical components from concept drawings to fabrication and testing of components. Specified parts and components, such as linear slides, motors, and gears to be installed onto finished mechanisms. Quoted parts from vendors and completed purchase requisitions through company purchasing representative.Utilized SolidWorks and GD&T dimensions to create drawings for machinists, welders, and vendors to fabricate critical parts.Developed prototype tape peeling machine for automated use for removing protective tape layer of LCD screen substrate. Produced prototype to reduce complexity over previous machine and to reduce time necessary to perform task. Prototype would be developed into production line mechanism.