Working on intra-oral cameras, blood plasma dehydration, cryo-anesthetics, ultrasonic imaging catheter workstations, a dash of ventilators, and heart attack predictors.

Medical device design, regulatory, technical troubleshooter for R&D and Manufacturing Engineering.Implemented ultrasonic welding for sealing xray sensors, replacing decades old tongue/groove adhesive method. Saved $90,000 / month labor. Welded joint 50% smaller than typical size limits achieved with collaboration with molder, weld equipment manufacturer, material compounder. Rigorous testing to ensure fragile sensor can survive weld shock. Specification of capital equipment, manufacturing procedures. Automation of critical optics assembly. Sensor assembly area was 300 square feet with capacity of 80 sensors / day. My mechanism designs changed it to 30 square feet with a capacity of 1,920 sensors / day - a 240x improvement in productivity. Key to miniaturization was the design of a double helix leaf spring.Project Manager for Multinational Design Team developing new product. Coordinating efforts in NY, PA, and Germany. EE, ME, Software, Physicists, Designers, IP, Marketing. Implement design controls, coordinating 510k submission.Thermal Modelling - Hot spots on surface of new product. Closed formed and FEA analysis led to successful redesign to make patient more comfortable.AimRight X Ray Positioning system. Made a kit with 5 molded plastic parts that can only be assembled 4 ways, each of which is usable. Replaced a kit of 11 parts which can be assembled in 512 ways, four of which are right. Required FEA, material research to replace metal parts with autoclavable plastic parts. Patented.Crack Propagation Modelling- Led effort to move away from long experimentation based iteration design cycles to analytically driven design methods. Developed an analytical model that predicted drop test survivability for adhesive joint designs. SAP optimizations for R&D Dept during MRP integration.Ran optimizations and developed usable profiles to transform a dead on arrival $15k 3d printer to a usable 1m x 1m x 0.5m build envelope, multi-material printer.

Medical device design, miniature x-ray & optical imaging devices. Injection, compression molded, LSR, sheet metal, machined component design, sourcing & qualification of new vendors, new manufacturing, new inspection techniques.Lead engineer on CDRElite product – developing 20 molds across two brands and five configurations. Improved shock resistance, waterproofing, maintainability, reduced RMAs. The product accounted more than 70% of the divisions profit the year it was released and received 4.8 / 5.0 rating by dentalproductshopper.comSwitch to vacuum metallization from conductive paints to solve debris problem while reducing hazardous waste streams. Match design to multiple vendor capabilities.Training and use of risk analysis for electrical, chemical, bio-burden, and mechanical hazards.Material & adhesive selections to bring products from FDA food contact to ISO 10993 compliant.

Projects involved java coding, graphic design, database access, and e-commerce. Custom built illumination FEA software built for greenhouse lighting company designed to IESNA standards. Utilized standard architectural lighting files as input, with GUI optimized around the client's existing workflow. Reduced time to design industrial scale greenhouse layouts by 80%.Implemented online store for merchants with web based backend that allowed for complete modification of online inventory with no knowledge of HTML.

Developed miniature analog controls for handheld electronics.Managed development of custom conductive rubber compound, supervised consulting polymer laboratory. Balanced manufacturability, cost, durability, chemical resistance. Final material, based on running shoe rubber, exceeded wear requirements by 10x.Simulation of voltage potentials in complex 3d shaped conductors using thermal simulation tools. Methodology used to rapidly simulate designs that previously required the construction of compression molding tools.Managed most extensive product compliance testing in company's history. Worked with internal and external resources.Author of technical reference materials for manufacturers to incorporate Varatouch components into their products.Implementation of parametric joystick design that automatically reconfigures parts, assembly, and drawing package with changes to joystick height and width, while maintaining manufacturability.

Designed scientific and biomedical research platforms using astronomy grade digital cameras, precision optical components, custom high output illumination paths, and micron-scale positioning mechanisms.Work on Gel electrophoresis, chemiluminescent and fluorescent imaging systems.Lead designer for flagship microarray reader product (4.5 micron resolution CCD based scanner, sub-pixel 3 axis micro-controlled ball screw positioning system). Most complicated product designed by the company to date. Lead cross-functional product team – scheduling, resource allocation, and on schedule launch. Supervision of consulting drafter, industrial designer, and optical expert.Authored document control procedure with electronic signatures and digital archive. Eliminated routing of paper authorization forms that were lost or misrouted, passed TUV audit 1st try.Managed installation of Intralink PDM system, updated procedures to formalize use, trained users, planned and executed legacy data migration. ProE Administrator.Support of existing products – production floor troubleshooting, improved manufacturing procedures with input from line assembly techs through management.Cost reductions on existing products, part count reduction for a slide holder from 50 to 12 and reduced assembly time 90% by designing a living plastic hinge. Replacement of $50 in custom metal parts with $1.20 in auto body panel clips. Elimination zoom/focus coupling problems in $500 lens with $1 ball nosed plunger.Managed first formalized customer site visits, observations, interviews, and documentation of product use environment. Resulted in 1/4" change in product height that dramatically improved workflow and reduced footprint of instruments that are used on crowded lab benches.US 20040150217 A1 Patent: “Identifying indicia and focusing target”

Employed by Mechanical Engineering Dept. and Haas School of Business. Created course on advanced CAD using Solidworks / Alias Studio Tools. Covered lofting, ruled surfaces, blending, NURBS. These techniques were then used to design for injection molding, mold modelling (with shrinkage / drafting / parting lines / side actions), derive sub-components from a master outer surface boundary, instantiating industrial design sketches.Created Injection Molding Lab. Students learned to run a real press and optimize cost / fill and finish of a lego-like part using factorial analysis.Changed DfM / DfA class to focus how the engineers will be interacting with marketing, customers, manufacturing, and other stakeholders in the process. Project groups in the class brainstormed a product concept, did benchmark research, surveys, formalized definition of customer needs & concept selection, cost analysis. At the end of the year they pitched their products along with prototypes. The students also got a tour of IDEO headquarters.\