Mechanical engineering intern, Global Security. Design, validation, and manufacturing handoff of custom inspection tooling.
Due to the nature of the work, specifics cannot be shared, so this is described at the method level. I independently led the design of a custom dimensional and alignment verification test jig, covering concept development, CAD modeling, FEA validation, mechanism design, GD&T, and design for manufacturability and usability. I also reverse engineered obsolete components to support continued operation of national assets.
A verification jig must be more accurate than the components it measures, which constrains the mechanism design and the tolerance scheme. It also has to be operable by personnel who did not design it, making design for usability a requirement rather than a secondary consideration. Reverse engineering obsolete parts requires reconstructing design intent from existing hardware without original documentation.
The jig progressed from concept to production. I collaborated with internal engineers and external manufacturers to refine design intent through the transition, and oversaw supplier work through on-site visits, advising process adjustments based on engineering analysis.