Coleman XL Wagon 

Collapsible multi-use wagon (2025)

As lead R&D engineer for the project, I played a critical role in the design and testing for the product, evaluating it under a multitude of metrics, including but not limited to:

• Structural strength - testing for ultimate and advertised loading, implementing frame improvements to meet targets
• Durability - testing for performance overtime, guaranteeing the product not only meets the warranty period, but will be reliable for many years thereafter
• Verifying marketing performance claims through testing and evaluation with legal department
• Product safety - evaluating and testing for adult and child safety risks
• Quality - reviewing off-tool samples for improperly fastened rivets, injection molding errors and issues, fabric quality

https://www.coleman.com/outdoor-living/furniture-sports/wagons/coleman-xl-wagon/SAP_2227034.html

Coleman "Stranger Things" Quad Chair 

Revamp of standard collapsible quad camping chair. (2025)

As lead R&D engineer for the project, I played a critical role in the testing for the product, evaluating it under a multitude of metrics, including but not limited to:

• Structural strength - testing for ultimate and advertised loading, implementing frame improvements to meet targets
• Durability - testing for performance overtime, guaranteeing the product not only meets the warranty period, but will be reliable for many years thereafter
• Quality - reviewing off-tool samples for improperly fastened rivets, injection molding errors and issues, fabric quality

https://www.coleman.com/outdoor-living/furniture-sports/camp-chairs/stranger-things-quad-chair-with-cooler/SAP_2225071.html

ROTARY KILN SHELL, GEAR GUARD & SUPPORT PAD SYSTEM

$4M equipment replacement project for a paper mill. (2024)

As Design Engineer for this project, I was responsible for the start-to-finish execution of the entire project's 3D CAD Models and 2D Engineering Drawings. I used previous drawings in addition to field data and surveying to select and design appropriately sized equipment. Below are sections describing various major components I designed for this project.

Fast Facts:

• Over 5,400 individual parts
• Total Weight of over 100,000 lbs
• 45 around-the-clock days to complete installation
• Entire project assembly is larger than most commercial airplanes

Drawings for this project are confidential, though examples of equipment are shown for reference.

Kiln Shell

• The main portion of this job is a ⌀ 126" and 372" long section of kiln shell, featuring various plate thicknesses used, ranging from 1"-2". 
• Required tolerances are so tight that the outer diameter must not deviate by more than 0.040".
• Shell is formed via rolling of half-sections of ASTM A36 Steel Plate, and has a total weight of 48,000lbs.

Base Frame

• To support the kiln's seven-figure weight, a steel base frame is used, composed of a series of I-Beams.
• This frame secures four support bearings, and two thrust bearings.
• ​It is mounted on a concrete column, known as a support pier.

Support Pad System

• Due to the extreme operating temperatures, Kilns are designed such that the riding ring is larger than that of the shell. Resultantly, there is a minor amount of relative movement between the two.
  
• To prevent wear on the shell itself, a series of metal pads are welded on, with a similar function and wear pattern to a car's break pads.

Riding Ring

• To enable rotation, mounted on the kiln is a large steel ring, known as a tire or riding ring. This ring makes contact with rollers on the support structure, and supports not only the vertical kiln load, but also the axial thrust loads.
• Similar to the kiln shell, diameter tolerances must not deviate by more than 0.040".
• The ring is formed via casting and subsequent machining, and has a weight of just under 30,000lbs.

Gear Guard

• The most complex component in this project is the gear guard, a lightweight metallic structure designed to hold gear oil and keep contaminants out.
• It is composed of 6 sections bolted together that form a protective circle around the gear. In the bottom is featured an oil tank with various access panels that enable maintenance personnel to inspect the drive and oiling pinions.

"SANDY" Robot

​Fast and agile 4 Bar Lift Robot (2018)

​The 4 Bar Lift Bot, codenamed "Sandy" is a robot designed by myself as the Team Captain, and other members of the Collins Hill Robotics Team. 

​Highlights:

• The design is just 12'' x 12 " when collapsed, but can extend to 50".
• Ability to go from min to max height in just 1.1 seconds
• Automated self-leveling system: sensors on either side of the robot count each motor's shaft revolutions. Data is fed to a program on the central computer that will slow two motors at a time until the system is level again
• Ultra low maintenance: only periodic joint oiling and elastic replacements required

"IVY" Robot

​Reliable, fast, and heavy duty scissor lift robot. (2017)

​The scissor lift bot, codenamed "Ivy" is a robot designed by myself as the Team Captain, and co-built by other members of the Collins Hill Robotics Team. The robot is notable for being one of the only robots of the season to successfully implement the infamous scissor lift. 

​Highlights:

• The design is just 12'' x 12 " when collapsed, but can extend to 66".
• Ability to go from min to max height in just 2.7 seconds
• Automated self-leveling system: sensors on either side of the robot count each motor's shaft revolutions. Data is fed to a program on the central computer that will slow two motors at a time until the system is level again
• Clever elastic system serves a similar purpose to an elevator counterweight- allowing the lift motors to only have to carry the difference, reducing lift times, motor effort, and power consumption
• Ultra low maintenance: only periodic joint oiling and elastic replacements required

Mercer Motorsports

FSAE vehicle engine mount design. (2021)

The Mercer Motorsports team needed an adjustable solution for mounting its drivetrain, that would allow for grace in the event of minor construction errors. I initially proposed the design pictured below, and with the help of classmates was able to further develop, test, 3D model, and run limited finite element analysis. 

Highlights:

• Series of independent adjustable members (total of 6)
• Compact, lightweight
• Cost effective and simple to manufacture
• Each member has ability to support 10x the design weight

​Work show below is non-confidential.

"SpaceMaker" Wall

Movable storage wall. (2020)

The SpaceMaker wall is a movable storage wall, designed for use as a partition and storage receptacle in small studio apartments.

Highlights:

• Near-hollow internals maximize storage space and save weight
• Sleek appearance seamlessly integrates into rustic spaces
• Cost effective and simple to manufacture