Projects

Situation / Problem

Field overheating pushed returns past a sustainable rate; needed a real fix to the thermal path, not a workaround.

Action

Phase 1: airflow + grill work (Flow Simulation + physical validation). Phase 2: stack upgrade (package + all-metal heatsink) to remove the junction-to-case bottleneck.

Result

−16 °C chip temp; returns under 3%; both phases shipped; ~+50% operating power vs prior gen.

Situation / Problem

No trustworthy batch screen before full commit; manual LIV was slow, operator-dependent, and weak on beam quality.

Action

Wood bench POC → two modular production fixtures (magnetic-swap LIV for packaged engine + Headers; optical beam sizing for the same form factors) plus the LIV test system spec for software.

Result

~3× batch throughput vs legacy; LIV + beam-size screening; technician-ready spec.

Situation / Problem

Critical press-fit relied on manual alignment and subjective checks; variation drove yield loss and escapes as volume grew.

Action

Three generations: bench concept → pneumatic pilot (GD&T + optical verify) → production poka-yoke with fewer DOF and constraint-driven tooling.

Result

Scaled toward ~1.5k units/week at ~95% FPY; architecture aimed at zero alignment-induced errors and ~3× throughput vs early tooling.

Situation / Problem

No COTS connector could join conductive yarn to standard electronics in a compact, manufacturable way.

Action

10 concepts → 3 via DFM/DFA; SolidWorks + printed prototypes; formal design review with 23 stakeholders.

Result

3 validated prototypes; two designs advanced into the Papyrus II program.

Situation / Problem

A commodity badge reel snaps back at 4.4 m/s, hammering the housing on every retraction and causing cord fraying, spring fatigue, and jamming across 10 to 15K cycles.

Action

Competitive teardown across three market tiers, four progressive design concepts (CF spring, TPU gasket, bumper spring, eddy brake), full spring spec, manufacturing process, COGS breakdown, and V&V test plan.

Result

Recommended concept brings end-of-stroke speed to effectively zero. $1.00 COGS at 500K units. FOS 5.1 on spring spec, rated for 50K+ cycles.

Situation / Problem

Needed a large, lightweight RC airframe that could carry a high-resolution survey camera with a wide field of view without guessing the airfoil or propulsion stack.

Action

Screened airfoils in XFLR5 (Clark Y selected), analyzed Cl/Cd/Cm vs AOA at 10 m/s, verified with wind-tunnel data; sized 1000 Kv / 343 W-class propulsion with bench thrust tests; hand-built Depron, balsa, and boxwood structure from blueprints.

Result

10 ft span / 7.5 ft fuselage / 3000 g target class; integrated ESC, LiPo, and servos; project featured in The Times of India.