Rapid Prototyping

Rapid prototyping is an essential component of my engineering process, enabling me to quickly turn concepts into functional prototypes for testing and refinement. Whether the goal is to evaluate design feasibility, test material properties, or validate manufacturing processes, I have extensive experience in using rapid prototyping methods to accelerate development cycles and optimize designs.

3D Printing (Additive Manufacturing)

Proficient in using FDM (Fused Deposition Modeling) and SLA (Stereolithography) printers to create high-fidelity prototypes, ranging from basic mockups to functional parts.
Expertise in designing models optimized for 3D printing, considering factors like material properties, print orientation, and support structures to reduce errors and improve the final product.

Laser Cutting

Skilled in laser cutting for creating intricate 2D prototypes, primarily for testing fit, form, and assembly.
Experience working with a variety of materials, including plastics, foams, adhesive sheets, and foils, to create custom components for assembly fixtures and functional prototypes.
Capable of fine-tuning laser cutter parameters (e.g., power, speed, frequency) to achieve precise cuts for small, intricate features.

Laser Welding & Heat Sealing

Experience in laser welding and heat sealing for creating durable, high-precision prototypes, particularly in the medical device industry where clean, consistent seals are crucial.
Developed and optimized fixturing for these processes, ensuring alignment and integrity during prototyping and manufacturing.

Laser Welding In Progress

Injection Molding & Soft Tooling

Knowledgeable in rapid injection molding techniques, including the use of soft tooling for short-run prototypes and material validation before committing to full-scale production.
Familiar with process parameters to create prototypes with accurate geometry, surface finish, and material properties.

Die Press

Experienced in operating die presses for precision cutting of materials.
Skilled in designing dies tailored to specific applications, ensuring optimal material utilization, clean cuts, and repeatable results.
Capable of optimizing die geometry and material selection to enhance process efficiency and extend tool life.

Die Press

Force Testing

Proficient in force testing methodologies for evaluating mechanical properties, material behavior, and product durability.
Designed and fabricated custom fixtures to interface with force testers, ensuring accurate and repeatable testing conditions.

Force Test Fixturing

Precision Microscopy & Metrology

Experienced in using precision microscopes, such as MicroVu, for detailed inspection and high-accuracy measurements of prototypes and manufactured components.
Capable of performing dimensional analysis, surface inspections, and quality control checks to ensure adherence to design specifications and tolerances.

MicroVu Precision Microscope

Tubing & Fitting Selection for Microfluidics

Material Compatibility & Flow Control: Select tubing and fittings made of materials like PTFE, PEEK, or Silicone for biocompatibility, and ensure appropriate inner diameter for controlling flow rates and pressure levels.
Leak Prevention & Efficient Assembly: Use secure fittings (e.g., luer lock, quick connect) for leak-proof connections, and choose flexible, kink-resistant tubing for easy integration and accurate flow path simulation during prototyping.

Fluidic Circuit Rapid Prototype

Material Selection & Validation

Ability to select the appropriate materials for rapid prototyping based on factors like strength, flexibility, biocompatibility, and cost.
Experienced in evaluating prototypes for material behavior under various conditions, including mechanical stress, thermal stability, and chemical exposure.

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