I saw this online and made it in SolidWorks when I had some free time. To see some pictures and drawings, you should
For my Intellectual Property class, I led a team to design a child stroller that allows one child to sit and another to stand behind. The overarching goal was to create a new, useful product that avoids infringement on other U.S. patents. We began by brainstorming novel features, and then used SolidWorks to create detailed CAD models, focusing on ergonomic design, safety, and market competitiveness. I fabricated and refined various components, ensuring functionality and manufacturability. To ensure we avoided infringement, we developed a claim comparison chart to demonstrate how our design differed from the existing patent. To practice protecting our intellectual property, I drafted a patent application that included specifications, technical drawings, a bill of materials, and well-defined claims. This project gave me hands-on experience in patent drafting intellectual property strategy, teaching me how to utilize my CAD to innovate while navigating the U.S. patent system.
During my co-op at Teradyne, two Stratasys 3D printers were heavily used, making parts that required frequent removal of soluble support material with the SCA 1200HCT cleaning system. However, after the parts were placed in the sodium hydroxide-based cleaning solution, there was no safe, efficient way to dry them. I address this outside of my normal work scope, designing a modular drying rack using SolidWorks while optimizing the geometry for airflow and drainage. I 3D printed the rack components, including four different perforated trays, allowing for stacking and efficient drying of parts of various geometries. After printing, I assembled the rack and validated its performance by drying freshly cleaned parts, which dried evenly and without damage. This project strengthened my knowledge of workflow optimization for post-processing for 3D-printed components.
For my Robotics Engineering course, I set out to model and control a virtual version of the Da Vinci Robotic Surgical System by Intuitive Surgical, a robotic platform used for minimally invasive surgery. I designed 11 custom parts in SolidWorks, including 10 articulated arm joints inspired by the serial linkage structure and EndoWrist mechanisms for dexterity. Using Denavit-Hartenberg parameters, I assembled the robot in MATLAB and developed a GUI with interactive joysticks, sliders, and input boxes, enabling real-time modification of joint angles and visualization of the Da Vinci's configuration. To emulate a surgeon’s console, I programmed a Raspberry Pi to interface with an Arduino with potentiometers and buttons to manipulate the simulation and LEDs to identify position singularities or self-intersections, mirroring the operation used during live procedures. This project deepened my skills in serial communication and human-robot interaction while providing insight into the integration of mechanical design, control systems, and user interfaces in surgical robotics.
When I lived at my fraternity house, I had selected a new, more spacious room to move into for my Master's year of college. However, its awkward layout, low ceilings, and need for renovations made it feel far from a fraternity home. I set out to transform the space into a functional environment that could serve as a living area, workroom, hangout space, and two-person room if I had a friend over. As any sane engineer would 🤨, I meticulously measured the room and all my furniture, creating detailed 3D models in SolidWorks for the room, couches, desks, bar, fridge, and more. Using these models, I experimented with different layouts to maximize space and versatility. Once satisfied, I removed the old furniture, painted the walls, redid the flooring, and built custom pieces like a desk, clothes rack, and shelves in the woodshop before moving everything in. The result was a comfortable, multi-purpose room that I was proud to live in and share with others - a true fraternity home that reflected my ability to bridge the gap between concept and execution.
For my Advanced Design of Mechanisms course, I modeled and simulated a front-end loader mechanism, similar to those used on tractors, to analyze its dynamic behavior and identify design improvements. Using SolidWorks, I created detailed models of the links, hydraulic cylinders, rocker, and scoop using 1020 steel to obtain accurate mass and inertial properties. This was imported into MATLAB, where I programmed the mechanism to join at each pin location and move through a full load and unload cycle using distance-driving constraints on the hydraulic cylinders. During the unloading, I incorporated the varying weights of the scoop’s contents and used the method of virtual work to calculate joint forces and actuator loads. By plotting 2D accelerations and extracting forces on each joint, I could weak points in the mechanism. This project deepened my skills in multibody simulation and force analysis while teaching me the importance of designing around kinematic movement.
A previous senior design team at the Reach Therapy Clinic was unable to finish an assistive walker due to safety concerns. I joined a new team tasked with making the device safe and functional for children ages 3–12 to use during physical therapy. Over two quarters, I led the redesign to address the handlebar strength and the height adjustment mechanism. For the handlebars, we selected a stronger material and used SolidWorks Simulation to ensure they could support a child’s full weight. I also worked to swap out the original height adjustment system with a fail-safe rack and pinion lift to incorporate mechanical locks and prevent accidental drops. After load testing, we verified the walker’s safety and usability. Completing this project not only addressed the clinic’s concerns, it also strengthened my skills in leadership and safety engineering.
When it comes to the dynamic systems of bicycles and wheelchairs, the radial stiffness and damping of tires aren't very well studied. For a research project on the dynamic systems of bicycles and wheelchairs, my team and I set out to investigate these two variables over a range of usable tire pressures. A robust drop-test apparatus was constructed using 8020 aluminum extrusions to ensure structural rigidity. I contributed to data acquisition systems and helped develop protocols to vary tire pressures and capture accurate acceleration data. We conducted multiple trials at each pressure setting, applying linear regression methods to remove outliers and verify repeatability. In addition to benchmarking our results against the limited literature online, I performed uncertainty analyses to ensure our results met a rigorous confidence interval. Throughout the project, I gained insights into test fixture design, experimental procedures, and data analysis. Our findings provided valuable insights into tire behavior under dynamic loading to better inform future endeavors to research dynamic stiffness and damping.
For my Mobile Robotics course final project, I integrated advanced navigation techniques into a mobile robot using wireless communication and a custom GUI. Over a month, I programmed the robot in Arduino IDE to execute topological navigation, metric path planning via wavefront algorithms, and localization using data from encoders and IR sensors. I also implemented simultaneous localization and mapping (SLAM) for the robot to map an unknown environment and track its position. Wireless communication was set up for bidirectional data exchange between the robot and a MATLAB GUI, helping visualize the robot’s position and planned paths. Through iterative testing in a structured arena, I explored whether topological or metric were most effective in different scenarios. This project deepened my understanding of robotic navigation, sensor integration, and user interface design.
The Terre Haute Fire Department faced issues with their Motorola walkie-talkies jamming during live fires due to air particles infiltrating the devices. By collaborating with a partner and several professors at Rose-Hulman, I worked to design a solution that could withstand the extreme conditions firefighters encounter. I researched high-temperature materials and designed a flexible injection molded silicone case that formed an air-tight seal around the walkie-talkie buttons. To ensure the design’s effectiveness, I conducted thermal performance tests in a furnace at temperatures up to 1200°F, analyzing material integrity and device functionality. The final enclosure successfully prevented air particle ingress while maintaining operability in harsh environments. This solution is now used for select Motorola walkie-talkies across the Terre Haute Fire Department and has been submitted to Motorola for consideration in future devices. This project strengthened my skills in collaborative materials testing and product development.
For my Measurements class, I was tasked with experimentally determining the drag coefficient for a semi-trailer truck. To achieve this, I designed and assembled a scaled model and set up a wind tunnel apparatus, measuring drag force with a force balance, air velocity using a pitot-static tube, and frontal area with calipers. After data was collected across multiple wind speeds, the drag coefficient for each trial and average was computed. Following this, a detailed uncertainty analysis was performed by propagating the errors from each measurement, with drag force identified as the largest contributor to overall uncertainty. Results were presented graphically and in tables, including tool accuracies and an uncertainty breakdown. The measured drag coefficient closely matched published values, validating the method and highlighting the importance of precise aerodynamic testing.
For my Mechatronics class final project, I addressed the challenge of automating the tedious process of cutting and stripping jumper wires. This is a big issue for the electrical engineering department at Rose-Hulman, where staff and student workers may spend hours doing this repetitive task. The objective was to design a cost-effective device that automatically produces wires to user-specified length, gauge, strip length, and quantity. I built a prototype using an Arduino microcontroller, two stepper motors for precise wire handling and cutting/stripping mechanisms, an IR sensor for wire detection, and custom 3D-printed components for motor, spool, and IR support. In the finished product, users input their desired wire specifications, and the machine processes spools of wire ranging from 10 to 26 AWG, cutting and stripping each wire accordingly. The result was a reliable, automated system that automatically produces hundreds of jumper wires, significantly reducing labor and increasing productivity. Not only did this project strengthen my skills in automation, rapid prototyping, and user-centered design, but it also provided a product that got regular use from students, reinforcing my desire to make solutions that benefit others.
For my Design for Manufacturing class, I was tasked with creating a practical product for everyday use. At the time, my friends and I were rewiring our desk setups, which inspired me to design a wire organizer to manage cluttered cables. I used SolidWorks to model the organizer, focusing on manufacturability and ease of assembly. The final design consists of two laser-cut sheet metal pieces, rubber bands for wire retention, and standard fasteners. The organizer accommodates up to nine wires of varying sizes and lengths, making it versatile for computer, phone, and ethernet cables. I fabricated the prototype using sheet metal bending techniques and tested it by rearranging my computer cables. The result was a sturdy, easy-to-use wire organizer that my workspace feel more organized. This project enhanced my skills in CAD modeling, prototyping, and applying DFM principles to solve real-world problems.
When my Design-Build-Fly team received a functioning RC plane missing several key components, I took on the challenge of recreating some of the parts. Using only the hole locations from the propeller motor and the plane’s body, I designed a new propeller mount in SolidWorks. I iterated through several designs, leveraging SolidWorks Simulation to ensure each version could withstand the stress of a motor spinning at tens of thousands of RPM. After optimizing the geometry, I 3D printed the mount and sanded the part to improve fit and durability. The final part fit snuggly and performed well during flight tests. This project strengthened my skills in CAD modeling and iterative design, showing me how I can leverage my skills to come up with solutions when project parts are missing.
In my Introduction to Engineering Design course, my team and I set out to address the challenge of moving suitcases up flights of stairs. For frequent travelers or those with mobility limitations, this is a common challenge. Our goal was to design a suitcase that made stair traversal easier and safer. We brainstormed and developed a concept featuring durable rubber treads integrated into the back of the suitcase. These treads would engage the stairs as the suitcase was tilted, allowing it to roll smoothly upward and significantly reducing the force required to lift or carry it. Over seven weeks, we collaborated to conduct user research, create initial sketches, perform force analyses, and develop detailed CAD models in SolidWorks. The project culminated in a comprehensive presentation of our final SolidWorks model, demonstrating a practical, user-friendly solution that reduced the force needed to move the suitcase by 20–45%, depending on the stair angle. This experience strengthened my skills in teamwork, CAD modeling, and the engineering design process.
For my Graphical Communications class final project, I was given the choice to design anything, so I decided to create a 3D model of R2-D2 in SolidWorks. Inspired by the challenge, I spent over 30 hours building the droid from scratch, using more than 350 features and referencing multiple internet images for accuracy. My goal was to push the boundaries of what could be achieved in a single solid model, demonstrating advanced CAD techniques such as lofts, sweeps, fillets, and complex assemblies. The project was entered into a school-wide competition against all other mechanical engineering students, and my R2-D2 was selected as one of the top five projects out of hundreds of entries. As a result, the Mechanical Engineering Department at Rose-Hulman 3D printed and displayed my model in their front office and used it to appeal to prospective students by showcasing the department’s emphasis on creativity and technical excellence. This project strengthened my CAD modeling and attention to detail.
For my Eagle Scout Project, I set out to solve a problem at my local Little League fields. The dugouts there were ill-equipped, and players had nowhere to store their helmets, often leaving them on the ground to get dirty or damaged. I took on the task of designing and leading the assembly of four helmet racks for the dugouts. Over six months, I developed a comprehensive project plan, including detailed design drawings, a bill of materials, cost estimates, and vendor lists. I selected durable lumber, hardware, and weather-resistant paint while outlining woodworking processes such as measuring, cutting, sanding, drilling, and assembling the helmet racks. On build day, I led a team of 12 Scouts and friends by delegating tasks, teaching proper equipment use for drills and nail guns, and ensuring safety. The finished racks now provide a clean, organized storage solution for the teams that play on the baseball fields. Not only did this project strengthen my project management, documentation, and leadership skills, it continues to benefit the community today.
For my senior year Civil Engineering & Architecture class, I was tasked with designing a preliminary two-story STEM building for my high school. Using Autodesk Revit, I created a comprehensive model, planning everything from classroom and hallway layouts to stairwells, window placements, and the structural design of both interior and exterior walls. I also incorporated electrical and plumbing systems, ensuring the design was functional and realistic. Throughout the project, I applied architectural drafting and space planning to adhere to building codes and plan for human traffic. When construction began the following summer, several concepts from my class – including elements from my own – were used as inspiration for the new STEM building at Amador Valley High School. This experience strengthened my architectural modeling and project visualization abilities, and it was rewarding to see my work contribute to a real-world project that benefits real people.
While I was a part of the PLTW program at my high school, I competed in a STEM-based competition (more to come later)