3D Printing with Mycelium-Based Materials

Explored environmental impacts of materials inoculated with mycelium in contrast with petroleum-based thermoplastic filaments to drive sustainability of 3D printing. Petroleum-based thermoplastics designed for cradle-to-grave processes presented an opportunity for a local, bio-based, renewable, compostable feedstock alternative to be developed and provide a more sustainable solution to bypass petroleum-based feedstock problems in Fused Deposition Modeling…

The PRO Kickstarter Campaign: DFMA Lifecycle

The Micro 3D printer was a success, but after 2 years, it was time to begin the second product design process. Collaborated with industrial design engineers, production managers, and an assembly crew to design a 3D printer for consumers, support part manufacturing for Asian suppliers, receive feedback from user technical issues, and develop plus test…

Redesign for Sustainability: Google “Molly” Set-Top-Box

Performed and presented, to Google, a Life Cycle Analysis of 6 eco-redesign ideas for Google’s 2014 Developer Set-Top-Box, codename Molly, with two other team members. A System Map was created to define Molly’s life cycle impacts, a product teardown was performed to collect the bill of materials information, and multiple life cycle assessments of various…

The Micro Kickstarter Campaign: Ramping up operations from nothing

Joined the 3D printer startup company as employee number 23 and as the 5th Mechanical Engineer. While production was working to quickly assemble, test, and ship ~11,000 units to fulfill Kickstarter rewards for backers, design the following systems: Product packaging for a Micro 3D printer, power supply, USB, and up to 4 filament rolls. Design constraint:…

Final Test Quality Operating System (QOS)

My Product Engineering Manager wanted to find out how much money was lost per device failed and per test parameter(s) failed. Current systems gave users the amount of semiconductor devices failed per wafer in quantity and percentage, but the current system didn’t have a connection to the cost models the accounting team used for each…

Lot Tracking System

Wafer processing cycle times had increased due to lots being “lost” on storage racks while awaiting the next fabrication process. This led to delayed engineering projects, missed production deadlines, decreased wafer quality, increase in rework processes, and increased product scrap costs. Assigned as the Project Lead to establish a new barcode and scan “Lot Tracking…

Wafer Fab Capacity Model

Researched 76 major semiconductor process tools (PECVD, Liftoff, Dry Etch, Sputter, Evap, Photolithography, etc.) with 14 Process Engineers and then wrote multiple Excel VBA scripts to quickly analyze process timing sequences from tool data logs to develop the first “Fab Capacity Model” and present manufacturing capacities per variations in product mix and product volume. Received a…

Autonomous Recyclables Sorter

Within a $500 budget for a capstone senior design project, a classmate and I collaborated to design, construct, and demonstrate a single-stream recycling machine that automatically sorted aluminum cans, glass bottles, and plastic bottles into specific bins using 1 ultrasonic sensor, 4 pressure sensors, 1 inductive proximity sensor, and a collection of tilt servos.