Other Projects

NOTE: Many of the projects listed below involve proprietary information, so details have been omitted & images have been sourced from similar, public projects.

Engineering Drawings for Assembly Fixtures in SOLIDWORKS

As part of a large Gener8 customer-funded project, I created ~200 engineering drawings from scratch using SolidWorks to support the design & fabrication of assembly fixtures for medical device manufacturing. My work included:

Defining Critical Features – Applied Geometric Dimensioning & Tolerancing (GD&T) to specify precise tolerances, thread types, fit callouts, and surface finishes, ensuring accurate part alignment and manufacturability.
Supporting Various Manufacturing Methods – Created drawings for 3D-printed, laser-cut, machined, injection-molded, and other fabricated parts, tailoring tolerances and callouts to each method’s capabilities.
Adhering to Standards – Followed Gener8’s engineering drawing templates and industry best practices to maintain consistency and clarity across all documentation.
Comprehensive Documentation – Developed both detailed part drawings and complex assembly drawings, incorporating exploded views and bill of materials (BOM) for streamlined production.

Due to the proprietary nature of these drawings, I have included these images, which are not my work but closely resemble the style and detail of my drawings.

How to prepare a technical drawing for CNC machining. (n.d.). Hubs. https://www.hubs.com/knowledge-base/how-prepare-technical-drawing-cnc-machining/

Drawing Format and Elements. (n.d.). Engineering Design. https://www.mcgill.ca/engineeringdesign/step-step-design-process/basics-graphics-communication/drawing-format-and-elements

Flow Cell for Prototyping Complex Molded Part Geometry

To prototype the mixing channel geometry of a molded part before committing to expensive tooling, I developed a laser-cut flow cell that accurately replicated the internal fluid pathways.

Key Contributions:

Rapid Prototyping – Used laser cutting to create a transparent model of the mixing channels, enabling quick iteration and design validation.
Visual Mixing Analysis – Conducted fluid flow tests to observe mixing behavior in real-time, verifying that the channel geometry effectively facilitated fluid blending.
Cost-Effective Testing – Allowed for early-stage design validation, reducing the risk of costly revisions in the molding process.

This prototype provided critical visual confirmation that the channel geometry promoted proper fluid mixing, ensuring confidence in the final molded design before proceeding with manufacturing.

Due to the proprietary nature of this prototype, I have included this image, which is not my work but closely resembles the laser-cut prototype.

Rapid Flow Cell Prototype Example

Brewer, L. R., & Bianco, P. R. (2008b). Laminar flow cells for single-molecule studies of DNA-protein interactions. Nature Methods, 5(6), 517–525. https://doi.org/10.1038/nmeth.1217

Molded Part Tolerance Stack & Process Capability Study

For a customer-funded project at Gener8, I conducted a tolerance stack-up analysis and process capability study to address variability in an injection-molded slide valve that was failing AQL standards due to inconsistent dimensions.

Key Contributions:

Tolerance Analysis – Evaluated the dimensional inconsistencies of the valve, microfluidic board, and clamp, identifying sources of variation affecting seal integrity and actuation force.
Process Optimization – Developed a complex equation that calculates the ideal collapse height for ultrasonic welding based on measured part dimensions, ensuring the correct interference fit for reliable valve function.
Adjusting AQL Standards – Although the slide valves failed AQL, they were successfully assembled and showed no functional issues. Using data and statistical proof, we were able to adjust AQL standards to reflect the true performance of the valves.
Operator Guidance System – Created an adjustment framework that allows operators to set precise collapse height parameters, compensating for molding variability in real time.
Process Validation – Conducted a capability study to confirm the effectiveness of the optimized welding parameters in maintaining consistent valve performance.

This approach significantly improved part yield and functional reliability, providing a data-driven solution to a critical manufacturing challenge while ensuring that usable parts were not unnecessarily scrapped.

Ultrasonic Welding Schematic

Ultrasonic Welders Admin. (2024, November). Ultrasonic Welding Guide. Sonitek Corporation. https://www.sonitek.com/blogs/news/ultrasonic-welding-guide

Microfluidic Cartridge Build & Documentation Effort

I played a key role in streamlining the assembly process and documentation for 1 lot of customer-funded microfluidic cartridges, ensuring consistency and efficiency in manufacturing.

Key Contributions:

Work Instructions & Process Documentation – Developed comprehensive assembly guides with clear visuals, capturing key parameters to ensure technicians could replicate the process independently.
Inventory Management – Cataloged all molded parts, off-the-shelf components, and fixtures to help the team anticipate material shortages for future builds.
Process Improvement: UV Glue Application – Solved a recurring assembly issue by designing a laser-cut adhesive mask that prevented UV glue spillage, ensuring proper clamp adhesion without interference.
Hands-On Cartridge Assembly – Built multiple microfluidic cartridges for customer delivery, involving laser welding of lyophilized beads in a dry room environment.
Manufacturing Implementation – The glue masking solution I developed was adopted into the formal manufacturing procedure.

Laser Welding In Progress

Laser Welder

Leister - Plastic Welding and Process Heat. (2025). LeisterTechnologies. https://www.leister.com/en/?_gl=1

Lyophilized Reagents

Lyophilized Reagents Solution. (2023, September 5). BEYONDBIO TECH. https://beyondbio-tech.com/cases-detail/lyophilized-reagents-solution

Ultrasonic Cleaner Process Capability Study

To validate the effectiveness of newly purchased ultrasonic cleaners, I conducted a process capability study assessing their ability to remove common contaminants from microfluidic injection-molded boards.

Key Contributions:

Contamination & Cleaning Validation – Intentionally contaminated boards with three common residues and cleaned them using Gener8’s standard ultrasonic cleaning process.
Quantitative Analysis – Captured before-and-after images and recorded contact angle measurements to assess cleanliness levels.
Process Qualification – Evaluated the efficacy of the cleaning method and provided data-driven insights to ensure the ultrasonic cleaners met performance expectations.

This study helped confirm the functionality and reliability of the ultrasonic cleaning process, ensuring effective contaminant removal.

Ultrasonic Cleaner

VEVOR Ultrasonic Cleaner 2L Digital Ultrasonic Parts Cleaner with Timer 40kHz Professional 304 Stainless Steel Ultrasonic Cleaner 110V for Jewelry Watch Glasses Diamond Eyeglass Small Parts Cleaning. (2024). https://www.vevor.com/ultrasonic-cleaner-c_11064/2l-stainless-steel-digital-dental-ultrasonic-cleaner-sonic-cleaning-equipment-p_010447073412

Laser Cutter Parameter Fine-Tuning for Precision Cutting

To achieve highly intricate and precise cuts on pressure-sensitive adhesive (PSA), I conducted an in-depth laser cutter parameter optimization process.

Key Contributions:

Iterative Parameter Testing – Adjusted laser power, speed, and frequency to refine cutting accuracy.
Microscopic Analysis – Measured laser-cut pieces under a microscope to compare actual cuts against CAD nominal dimensions.
Process Optimization – Identified ideal settings to minimize deviation and ensure the PSA matched the CAD design as closely as possible.

This fine-tuning process enabled the accurate fabrication of small, intricate features, ensuring the PSA met design specifications.

Laser Cutter

Epilog Laser Engraver/Cutter | FabLab. (2022, February 9). FabLab. https://www.lakeshorefablab.com/product/laser-etcher/

Laser Welding of Mesh onto Plastic Part Process Development

As part of a research project, I explored the feasibility of laser welding mesh material onto polypropylene (PP) plastic parts. This task required designing custom fixturing to securely hold the molded PP parts and mesh material during the laser welding process.

Key Contributions:

Fixturing Design – Collaborated with a teammate to design and develop custom fixtures that precisely aligned the mesh material and PP plastic parts during laser welding. This involved rigorous iterations to optimize fixture stability and ensure consistent welds.
Process Validation – Conducted multiple test runs to validate the welding process, adjusting parameters such as laser power, speed, and focus to achieve optimal bonding without damaging either the mesh, PP part, or associated fixturing .
Conclusion – After several successful trials, the project confirmed that laser welding was indeed a viable method for bonding mesh material to PP plastic, with the resulting welds meeting performance and durability standards.

This research has provided valuable insights for future manufacturing applications at Gener8, where mesh and PP plastic materials often need to be combined.

Heat Sealing Process Development & Fixture Design

At Gener8, I have played a key role in developing heat-sealing processes for a wide range of complex molded part geometries across multiple projects.

Key Contributions:

Fixture Design & Process Development – Designed custom fixtures to accommodate diverse plastic injection-molded parts, ensuring consistent and high-quality heat seals.
Material Selection & Process Optimization – Worked with various foils and membranes, optimizing sealing parameters for materials used as vents, barriers, and liquid containment layers.
Testing & Validation – Conducted flow and leak tests to verify seal integrity and performed process capability studies to ensure repeatable and robust welds.
Automation & Ergonomic Improvements – Explored automation solutions to enhance efficiency and repeatability while implementing ergonomic enhancements to improve technician workflow.
Technical Documentation – Authored comprehensive work instructions and managed work orders to support production-scale implementation.

My innovative fixture designs and high-quality welds have consistently impressed customers.

Page updated

Report abuse