Manufacturing & Process Engineering
I translate complex, floor-level issues into documented, repeatable processes that teams can execute. The projects below highlight outcomes first, with technical depth available in each case study.
Aerospace Investment Casting Process Engineering
Structural Inconel 718 components | Tier‑1 aerospace supplier
Summary
Owned the manufacturing process for structural Inconel 718 investment castings in a regulated aerospace environment, leading cross-functional efforts to eliminate cracking, stabilize dimensional performance, and improve first-pass yield.
Engineering Problem
Dimensional variation and cracking in structural nickel-based superalloy castings created rework, audit risk, and unacceptable first-pass yield.
Actions
- Served as process engineer owner from casting through inspection, coordinating with quality, operations, and the floor.
- Updated work instructions and travelers to align with latest drawing revisions and approved manufacturing methods.
- Supported die rework, gating modifications, and execution approvals as a Tier‑1 supplier.
Results
- Improved first‑pass yield through process stabilization and structured troubleshooting.
- Eliminated cracking via gating/feeding changes and inspection control.
- Improved audit readiness through standardized documentation and traveler control.
Tools & Methods
Investment casting (lost‑wax) • NCR/MRB • Excel capability analysis • Controlled work instructions & travelers
Images are representative of similar aerospace investment casting processes. Specific components and tooling are not displayed due to confidentiality and export-controlled restrictions.
Casting Design & Solidification Simulation
ProCAST | Virtual validation + physical pour
Summary
Used solidification and flow simulation to validate casting design decisions before production, reducing risk by identifying fill behavior, hot spots, and shrinkage risk prior to tooling or pours.
Engineering Problem
A proposed casting design carried risk of shrinkage, porosity, and incomplete fill—potentially causing scrap, rework, or costly tooling changes if discovered after release.
Actions
- Designed casting geometry including gating and riser systems.
- Simulated fill progression, temperature gradients, hot spots, shrinkage risk, and solidification time in ProCAST.
- Iterated the design by flipping part orientation, redesigning gating, and resizing risers to improve feeding.
- Re-ran simulation to confirm improved solidification behavior before physical execution.
Results
- Reduced technical risk prior to manufacturing investment.
- Improved confidence in casting quality before tooling/pours.
- Demonstrated simulation-backed DFM decision making.
Tools & Methods
ProCAST • Gating & riser design • Solidification analysis • Virtual validation prior to pours
Media shown is from academic simulation work; no proprietary tooling or production components are represented.
Welding Process Monitoring & Quality Control
Hardware + dashboards | Data-driven operator feedback
Summary
Implemented weld monitoring and data-driven feedback loops to improve weld quality, reduce defects, and increase throughput across production welding operations.
Engineering Problem
Inconsistent weld quality and limited traceability led to low yields, rework, and delayed part flow through inspection and NDT.
Actions
- Implemented Miller weld monitoring to capture voltage, current, time, and pass/fail limits.
- Built dashboard views for operators and quality to review trends, out-of-spec events, and corrective actions.
- Created feedback loop to reduce repeat defects and stabilize weld output.
CAD Assembly Demonstration
Inline‑4 crankshaft + pistons | Assembly constraints | CAD communication
Summary
Modeled an inline‑4 crankshaft and piston assembly to demonstrate mechanical design fundamentals, assembly constraints, and clear CAD communication.
Tools & Methods
Fusion 360 (this assembly) • SolidWorks • Autodesk Inventor • Parametric modeling • Mates/constraints • Drawing-ready geometry
High‑Speed Beverage Can Manufacturing Reliability
Continuous-run, high-volume production support
Summary
Provided hands-on reliability and manufacturing support for high-speed, continuous-run aluminum can end production, improving uptime and stability in an environment producing millions of units per day.
Engineering Problem
In extreme-throughput production, unplanned downtime and equipment faults can immediately impact output, quality, and downstream operations.
Actions
- Supported continuous-run automated equipment with hands-on troubleshooting during live production.
- Worked with pneumatic and hydraulic systems, PLC interfaces, and industrial sensors.
- Assisted in identifying repeat failure modes impacting uptime and stability.