I see the connections and bridges that product development often misses: between the disciplines, the teams that own them, the customer they are all building for, and the product itself.
My design depth is mechanical and electrical. Firmware I hold my own in. Software I architect, direct, and integrate rather than write from scratch.
Below is fifteen years of shipped work, not claims.
Where the disciplines connect
The same person across every discipline, zero distance between them. A driveline, a whole machine, and a tool, each one several disciplines in a single object.
Mechanical and fabrication
CAD allows anything to be drawn, including parts that cannot actually be made, or cannot be made easily. I learned fabrication, welding, machining, and electrical work before I learned CAD, so I design knowing how each part will actually be built. That makes the jump from CAD to real parts a smooth one.
Equal-length headers and megaphones, designed from a 3D scan and fitted to the car. The challenge is routing and packaging eight equal-length runners, merged by the overlapped and evenly pulsed firing order, around the spark plug wires, leaving room to pull valve covers, and holding everything tight to the engine while preserving clearance to nearby components and the body. 3D scan to CAD to fixtures to finished part, one person across the whole chain.
Electrical and PCB
A deep understanding of the electrical side is what connects the mechanical and the firmware.
A robotic retail vending program, 25 people across three regions. After several course corrections, I took over the robot stepper control PCBAs and drove the robot toward design-for-assembly and design-for-manufacture under a tight timeline, coordinating across the hardware, firmware, and software teams. Delivered within 2 percent of scoped cost and to my quoted timeline.
Machine control and motion
The vending machine and weld positioner above are clear examples of mechatronics. Two more below.
Software and tools
Suspension Geometry Ninja is a commercial suspension design tool I architect and direct. Built to fill a gap neither the existing tools nor SolidWorks cover: a full suspension design and analysis workflow. suspensiongeometryninja.com
The live 3D view with Ackermann and instant-center trails. The geometry updates as you move it, which is the part neither the existing suspension tools nor general CAD give you in one place. It imports CAD to reference the space a suspension has to fit, and exports its points as IGES to keep building in CAD. CAD severely bogs down on this geometry and cannot give you the full-travel suspension specs and behaviors, which makes designing suspension in it frustrating and close to impossible. Closing the gap between the tools is less about saving time than seeing the suspension behaviors and letting the design actually flow.
Reverse engineering and 3D scan-to-CAD
Measure or scan the part, rebuild it in CAD, then prove the rebuild against the scan or with a printed test fitment. Often to reproduce parts that are no longer available.
An automotive air intake, 3D scanned and reverse-engineered to reproduce a part that is no longer available. The purple and green is the raw 3D scan laid over the finished CAD, so the match can be checked surface by surface.
Validation and measurement
A design is only a hypothesis until it is measured and certified. Thermal, dimensional, endurance, IPX4, EMC: the certifications are where the plan proves out. The 250,000-cycle result and the low field RMAs are just the receipts. On one treadmill line, full-machine factory returns went from roughly 90 percent to roughly 3 percent.
SCARA robot for automated retail vending. Its bent sheet-metal structure was run through 250,000-cycle endurance testing, and the whole machine then passed EMC, IPX4, and surge-immunity qualification as a complete unit.
If this page has you thinking about your next build, you likely already know if I am the right fit.