Manufacturing Intern
- Produced dimensioned CAD models and manufacturing drawings from existing physical components in SolidWorks, reconstructing geometry, tolerances, and GD&T callouts for legacy parts lacking documentation; drawings were released to production and used to manufacture parts.
- Designed and deployed the shop’s production quality-control system, replacing a paper-based inspection workflow with enforced dimensional verification that hard-stops a job when a reading falls out of spec, staging inspection from casting to first-article to QA-approved-to-ship with blind re-measurement; used daily by 6 machinists across ~10 work orders per day.
- Operated manual lathes independently across the full job scope — interpreting drawings, planning operation sequence, selecting tooling and speeds/feeds, and performing in-process dimensional inspection to hold specified tolerances.
- Manufactured precision components on CNC mills and lathes, frequently operating 2–3 machines concurrently and holding tolerances as tight as ±0.001 in.; proposed revised CAD designs of existing components to improve manufacturability and reduce machining operations.
Sleeved Roll Training Assembly
Bemco manufactures rolls for the steel mill industry and originated the sleeved roll design. A solid roll wears out where the impact lands, so Bemco redesigns it as a hub carrying one or two sleeves. A worn sleeve can be reversed to use its unworn side, and the two sleeves can be swapped. Two sleeves with two usable sides each gives four times the service life of a solid roll.
I built scaled training versions of the full two-sleeve assembly. I modelled the hub, sleeves and ring in SolidWorks, produced dimensioned drawings with section views and chamfer callouts, machined the parts on manual and CNC lathes, and assembled them to check fit.
From Part to Drawing
These parts I made had no drawings. They were legacy components, and the only record of the geometry was the part itself. I measured them and rebuilt them in SolidWorks including geometry, tolerances and GD&T callouts.
Machining from Drawings
Working from supplied drawings on manual and CNC lathes: reading the drawing, planning the operation sequence, selecting tooling and speeds and feeds, and inspecting in-process to hold the specified tolerances.
Production Quality Control System
Bemco machines rolls and roll components for the steel mill industry to tight drawing tolerances. Inspection was tracked on paper, where a measurement only got verified if someone remembered to verify it. I designed and built the system that replaced it, now used by six machinists on shop-floor tablets.
The office issues a work order carrying the customer, drawing number, casting count, and the dimensions and tolerances for every operation. On the floor, each casting is screened proceed or not-proceed before any machining time is spent on it. Operators then record actual measurements against each dimension, checked against tolerance as they are entered.
Screens shown use demonstration data. The same system is covered from the software side under Experience › AI & Software.
Retaining Wall
Designed and built a retaining wall sized to block falling trees. Base excavation proportioned to wall height, gravel drainage layer to mid-height with drain pipe to relieve hydrostatic pressure, and a setback every two courses to resist overturning.
Front Suspension Team (1st Place Overall OktoBAJAfest)
- Conducted design and manufacturing of the front suspension for an SAE Baja off-road vehicle by independently researching manufacturing methods and design trade-offs under competition constraints.
- Improved prior suspension design, contributing to 1st place finishes in Hill Climb (15.72 s), Short Track (24.32 s), Baja Cross (79.07 s), and Endurance under varied dynamic loading conditions.
- Redesigned and modeled suspension components in SolidWorks, including the spherical plain bearing (uniball), conducting iterative design refinement to optimize strength, manufacturability, and assembly integration.
