Markforged (2021 - present)
Worked on both the FX20 and [REDACTED, STILL UNDER DEVELOPMENT] as a senior mechanical engineer specializing in thermal system design. Primary responsibilities have been designing the heating systems for next-generation industrial printers capable of printing both standard and high-temperature plastics (Ultem etc) and metals.
Wide scope of responsibility: standard CAD and mechanical design work, thermal system design using a variety of techniques (hand calcs, FEA/CFD simulations, empirical testing with sensors & instrumentation, etc), interfacing with vendors to source components, and hands-on testing and troubleshooting of the system during development. Also took on some mentorship and guidance roles for junior engineers on the team as needed.
SAAM Inc. (2020)
Short-term contract as senior mechanical engineer at a startup, parachuted in to take point on their product development and help them get from rough design to having the first six functional prototypes built & tested in four months.
Product was a consumer electronics device - a smoke, fire, gas, & air quality sensor utilizing NDIR spectroscopy and a novel opto-mechanical design to sense ambient air makeup with much finer limits of detection than existing consumer devices.
“Wear all the hats” role - mechanical design, hands on machining & fabricating, PCB layout & assembly, writing software, systems integration, testing & validation, DFA/DFM etc.
Formlabs (2018 - 2020)
Worked on the Fuse 1 SLS printer as a mechanical engineer. Primary responsibility was supporting product development & NPI, taking the printer from a mature prototype to a finished & shipping product. Lots of troubleshooting complex electromechanical systems, fixture & test jig design, updating CAD assemblies & drawing packages, modifying and redesigning parts, and focused testing & troubleshooting to address high technical-risk areas of the overall mechanical design.
Also led the SLS build team, in addition to my individual responsibilities above. The team consisted of ~5 technicians, and was responsible for building, operating, upgrading & troubleshooting all prototype & development printers. Primary responsibilities were coordinating individual team member's efforts on a day-to-day basis, implementing scalable & effective organizational strategies within the team, and cultivating the continual growth and skill development of team members.
Trulson Design (2016 - present)
Founded a design & fabrication business to handle freelance machining work and other contract/project-based mechanical engineering jobs that had begun to come up more frequently.
Provides mechanical engineering, design, and prototyping services, supported by in-house CNC machining and a wide range of fabrication capabilities. Specializes in designing and building prototypes and providing support through the entire product development cycle, from initial proof-of-concept through to high-volume manufacturing. Particularly useful in support of hardware startups and other small, focused, product teams.
Orbit Research (2015 - 2017)
Worked as a mechanical engineer at a product development company making assistive technology for the blind. Primary products worked on were a refreshable braille reader ("Orbit Reader 20") and a full-page tactile graphics display ("Graphiti")
Fast-paced environment, working with a globally distributed team. Strong focus on leveraging intelligent design of mechanical components to deliver high-value products at a lower cost to the end user. Involved routine design of plastic parts for injection molding, and metal and plastic parts for in-house CNC machining.
Primary responsibilities were proof-of-concept design and verification, creating multiple prototypes throughout an iterative design cycle, continual testing during prototype development, sourcing parts and interacting with vendors, and refining designs for cost-effectiveness and manufacturability.
Proposed and led the development of in-house CNC machining capability, to support a growing need for quick & effective prototyping. Took on the role of primary CAD/CAM designer & CNC machinist. Most machining done on a Tormach PCNC770 mill, with occasional manual lathe work. Parts were largely one-off fixtures, test jigs, and multiple prototype parts during design iterations, with some small production runs (5-50 parts).
Wet Dog Glass (2014 – 2015)
Worked as a mechanical engineer supporting the design, manufacture, and operation of studio glassblowing furnaces and equipment. Highly custom manufacturing environment. Examples of work done include developing a calculator to find the heat loss and inter-wall temperatures in a variety of equipment, calculating ventilation requirements for equipment exhaust, sizing gas springs for assisted-open lids, and creating a utilities calculator to estimate electricity and fuel usage and costs for a given hot shop.
Worked on the shop floor building glassblowing furnaces and equipment. Responsibilities primarily involved metalwork (cutting, machining, welding, and surface finishing, mostly of steel and aluminum), refractory work (bricklaying, casting refractory components, installing high-temperature fiber and board insulation), electrical & control panel wiring, and a variety of general shop and fabrication work.
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