Integrated Design

 As part of ME250: Design and Manufacturing I at the University of Michigan, I worked in a small team to design, build, and compete with a fully functional robot for a cube-handling challenge. The objective was to develop a mechanical system capable of knocking cubes off elevated platforms, pushing them across the field, and depositing them into a model “space shuttle.” The project emphasized end-to-end engineering: from concept generation through physical prototyping and final competition performance.

 I contributed across all major phases of the design cycle. I used CAD tools (SolidWorks) to model the robot’s chassis and cube manipulation mechanism, ensuring our design met tight dimensional, mechanical, and functional constraints. I also machined several of the core structural components using mills, lathes, and other manual tools in the student shop. In the assembly phase, I helped wire and solder the control system, integrate the planetary gearbox motor, and validate full system operation through iterative testing and refinement.

 This project required close attention to mechanical tolerances, weight balancing, gear ratios, and drivetrain performance under load. Through testing and adjustments, we successfully achieved the required functionality, and our robot performed reliably during the final class competition. The experience strengthened my hands-on skills in mechanical fabrication, electromechanical integration, teamwork, and system-level thinking—all directly applicable to complex robotic systems in aerospace and exploration missions.

 Here is the slideshow presenting our design work and a video I made for it.

 During my internship at KEEL/MERRILL, I was selected to represent the company at the 2025 Automate Detroit conference—a major industry event focused on robotics, industrial automation, and advanced manufacturing technologies. The event brought together engineers, manufacturers, and technology leaders to explore cutting-edge solutions aimed at improving efficiency, precision, and scalability in production environments.

 Attending on behalf of my company, I had the opportunity to engage directly with emerging technologies including robotic arms, machine vision systems, PLC-controlled automation setups, and autonomous material handling solutions. I observed demonstrations from leading robotics firms and gained insights into how flexible automation can be adapted for different industries—from aerospace and defense to automotive and consumer goods.

 This experience gave me a deeper understanding of how mechanical design, control systems, and software come together in real-world factory settings. It also reinforced the importance of designing solutions that are not only technically sound but also scalable, serviceable, and cost-effective. Seeing these systems in action sharpened my perspective on systems integration and helped inform my work back at KEEL/MERRILL, where I was involved in developing support structures for high-load welding operations.

 After a soccer injury limited my mobility and before I was eligible to drive, I designed and built a high-speed electric bicycle to regain independence and explore electric propulsion systems. Starting with a standard bike frame, I engineered a custom electric drivetrain powered by a repurposed RYOBI leaf blower battery, achieving peak speeds of up to 40 mph.

 I sourced and integrated key components—including a throttle controller and a rear-wheel gearbox—and configured the circuitry to safely and efficiently deliver power from the battery to the motor. This required voltage matching, wiring stabilization, and testing under load to ensure reliable performance. Mechanical integration included adapting the drivetrain to the frame, aligning the gear system, and reinforcing the structure to handle higher speeds and terrain stress.

 In later iterations, and after an unfortunate off-roading incident, I added foam-filled tire inserts (pool noodles) to prevent tire blowouts during off-road use. This design upgrade allowed for improved durability and performance on trails, reducing the risk of flats while maintaining ride quality.

 This self-initiated project combined electrical and mechanical engineering principles to create a fully functional, real-world mobility system. It challenged me to work through system-level design, power delivery, safety considerations, and iterative testing—all of which deepened my hands-on engineering experience and creative problem-solving skills.