Starship Electronics Manufacturing

Starship Structures Manufacturing- Tank qualification article build owner- Ship Aft Integration build engineer- Ship Aft Skirt Thermal Protection System design & build

Gave lectures and demonstrations on manufacturing processes including CAD/CAM, CNC machining, injection molding, composite layups, and GD&T; trained other TA's and students on CNC machines.

Manufacturing Engineering - Components Engineering TeamFalcon Valves

• 2WD Powertrain: Led team’s decision to move to RWD based on team goals, performance, and risk factors in PDR; compiled motor selection comparing 33 motors across 30 parameters with gearing estimates for optimization sims; leading team as DRI of the subsystem and aiming to design custom electronically controlled limited slip differential.• 4WD Powertrain: Redesigned upright & gearbox for DB configuration to improve load capacity with lighter AC bearings, improved bolt accessibility for assembly & maintenance, reduced unsprung weight by 10%, FEA for combined driving loads; lead high level design, conducted design reviews, hands-on manufacturing & assembly.• Swan Necks: Designed rear wing mount, reduced weight by >50% while keeping min SF of 2.5, conducted static FEA and buckling calculations of 4-part linkage representing boundary conditions with loads derived from CFD analysis.• Project Management: Led team of 7 in design of 4WD powertrain; handled system integration & schedule, focus on knowledge transfer & documentation, meeting tight deadlines; organized online “internships” for Summer 2020, gave actionable feedback in design reviews, guiding 8 teams through design process starting from first principles.

• Restored 4-axis CNC mill, debugged faults, self-taught operation from the manual, generated and debugged G-code in MasterCAM ultimately getting it fully operational, & wrote condensed user guide for future users.• Assisted students in manufacturing engineering course with tool selection and ensured safe machine use.

• Designed two 3D printed orthopedic drill demos to display motors and motor controller drill/tap modes.• Designed sprung air collet rotor-stator assembly fixture to improve speed by 20% and prevent assembly damage.• Improved production on $12M account with easy to use clamping fixture, used ~500 cycles/day on torque tester.• Modeled 2 skewed rotor magnet configurations designed to improve startup behavior, made drawings with GD&T.

• Managed production operations over summer and for the year, supplying 100’s of parts to research labs at Penn.• Operated and maintained 3D Printers: Fortus 450MC, Objet30, ProJet6000, MakerBot Replicator, Prusa i3 MK3.• Learned FDM, SLA, and Inkjet processes for consultation of use cases, resolution, material properties, and cost.