Automated Motor Validation
& Test Framework — OPEX
Mechanical Design Engineer
Developed a Python-based automation framework that replaced 200+ manual user actions per test cycle, previously taking ~15 minutes, with a fully automated workflow capable of running independently after initialization. Designed the system to allow parallel test execution, enabling multiple motor validation tests to run simultaneously and significantly increasing throughput. The framework incrementally commands motor speeds, monitors current response, and detects failure thresholds, providing consistent and repeatable validation across multiple robotic product lines. Integrated the automation with custom flywheel-based test setups to simulate real-world loading conditions. Additionally, designed the interface to be intuitive and operator-friendly, allowing non-technical technicians to easily execute complex validation procedures with minimal training, improving efficiency, consistency, and overall quality control.
Multi-Bay Impact Life
Testing System — OPEX
Mechanical Design Engineer
Designed and developed a multi-bay drop testing system to evaluate the durability and impact performance of cushioning foam used in package handling within the SureSort robotic sorting system. Simulated real-world conditions where packages up to 25 lbs are dropped onto conveyors by engineering a robust fixture capable of cyclically dropping 25 lb weights across four independent test bays, each with its own test sample. Redesigned structural components and machined custom parts to ensure durability and consistent operation under repeated impact loading. Integrated a vibration-based fault detection system to automatically stop testing in the event of abnormal behavior, and implemented a cycle-counting mechanism to track drop counts for each bay. The system provided reliable, repeatable data for material validation while ensuring safe, long-duration testing under realistic operating conditions.
Bench-top Flywheel Motor
Validation System — OPEX
Mechanical Design Engineer
Designed and developed a benchtop flywheel testing system to simulate real-world loading conditions for motor and drive assemblies under controlled environments. Translated in-system load requirements into an equivalent flywheel-based setup, enabling incremental speed testing while monitoring current response and identifying failure thresholds. Engineered and assembled precision-balanced flywheels to ensure smooth high-speed operation, and integrated the system into a table-mounted fixture for stability and repeatability. Designed and fabricated a sheet metal enclosure to safely contain rotating components and mitigate risks associated with high-speed testing. The system provided a reliable platform for validating motor performance, supporting quality control efforts, and ensuring safe, repeatable testing of critical electro-mechanical components.
Chemical Exposure & Cable
Life Testing —Teleflex
New Product Development
Executed FDA-compliant validation testing on cable assemblies to evaluate durability under chemically aggressive and humid conditions. Exposed cables to abrasive environments (bleach and hydrogen peroxide) at controlled humidity for 24 hours, followed by cyclic fatigue testing using a cable tester that twists the cables while monitoring signal integrity. Configured and operated the testing system, including learning a new programming interface to define test parameters and data collection. Conducted lifecycle testing to failure, recording results across multiple samples and linking performance to manufacturing lot data. Analyzed variability in failure behavior and applied statistical methods to determine whether the cable population met reliability and compliance requirements, supporting successful product validation for release.
Kinematically-Constrained
Twist Load Test Fixture — OPEX
Mechanical Design Engineer
Designed and developed a custom test fixture to simulate a critical real-world failure mode (“three-wheel jam”) in robotic systems, where asymmetric wheel engagement induces high torsional loads that can cause structural failure. Engineered a kinematically constrained mounting system to secure three wheels without over-constraining the robot, while replacing the fourth wheel with a custom eccentric wheel to introduce controlled lifting and twisting during operation. During testing, identified failure modes in the constraint system that led to unintended contact and premature fixture failure, prompting a redesign of both the constraint bracket and eccentric wheel, which were machined and validated to improve reliability and accuracy. The final configuration forced energy into the frame and braces as torsional load, accurately replicating worst-case conditions. Conducted iterative life testing of brace designs, enabling evaluation of structural improvements and guiding design decisions to mitigate frame failure.
Contra-Rotating BLDC Validation
Test Stand — Senior Design
Lead Mechanical Engineer
Designed and built a custom thrust test stand to validate supplier-provided thrust vs. current performance for a contra-rotating dual BLDC motor system. Developed a controlled experimental setup that allowed independent power control of upper and lower motors, enabling analysis of thrust dependency on current distribution between stages. Conducted parametric testing by varying propeller pitch, diameter, and spacing, including validation of a CFD-predicted ~30% thrust efficiency improvement through optimized propeller configurations. Instrumented the system to measure thrust output and monitored motor temperature to ensure safe operation during extended testing. Generated performance curves and comparative plots to identify optimal configurations based on thrust, power consumption, and thermal constraints, directly informing design decisions for system efficiency and performance.
