— PROJECT NAME

Megawatt Electrolyzers

— SKILLS UTILIZED

- Mechanical Design

- 3D Modeling

- Quality Engineering

- Design for Manufacturability

- Procurement

Contributed to the development and validation of next-generation megawatt-scale electrolyzer platforms (PEM & AEM) through three core focus areas:

1. Mechanical Design

• - Led redesign efforts for critical electrolyzer components to improve performance and manufacturability
• - Created and iterated 3D models through structured brainstorming and collaborative design reviews
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2. Quality Engineering

• - Applied DFM principles to optimize designs for scalability and cost-efficiency
• - Produced detailed technical drawings with GD&T annotations
• - Conducted part inspections both pre- and post-failure (root cause analysis)
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3. Design Validation

• - Performed mechanical testing of custom components
• - Participated in hands-on assembly and teardown of full systems for fit, function, and durability evaluation

— PROJECT NAME

Lab-Scale Electrolyzers

— SKILLS UTILIZED

- Mechanical Design

- 3D Modeling

- Quality Engineering

- Design for Manufacturability

- Procurement

Led the full redesign of the lab-scale electrolyzer platform used for cell testing—delivering significant improvements in durability, testing functionality, and ease of use over the previous generation.

Collaborated closely with R&D scientists and senior mechanical engineers throughout the project. Responsibilities included:

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• - Identifying initial design challenges and leading brainstorming sessions
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• - Creating and refining 3D CAD models and performing key mechanical calculations
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• - Managing design reviews, part sourcing, and DFM considerations
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• - Conducting part inspections and functionality testing
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• - Overseeing final assembly and handing off the completed system to the R&D team

— PROJECT NAME

Electrolyzer Test Stands

— SKILLS UTILIZED

- Mechanical Design

- 3D Modeling

- Systems engineering

- Mechanical assembly

Collaborated closely with systems and process engineers to design and build in-house electrolyzer test stands from the ground up.

Converted detailed P&IDs into full 3D CAD assemblies comprising hundreds of components, including major equipment, instrumentation, fittings, piping, and structural supports.

Key contributions included:

• - Translating process schematics into manufacturable mechanical designs
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• - Creating complex assemblies in CAD for multi-system integration
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• - Participating in all aspects of physical assembly, including:
• 1. Frame construction and equipment mounting
• 2. Pipe bending, fitting, and instrumentation installation
• 3. Basic electrical wiring and system integration
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• - Supporting commissioning and troubleshooting of the completed system

— PROJECT NAME

Custom Fixtures & Miscellaneous Design Tasks

— SKILLS UTILIZED

- Mechanical Design

- 3D Modeling

- Mechanical assembly

- Design for Manufacturability

- Rapid prototyping (3D printing, laser cutting, CNC machining, and power tools)

- Procurement

In addition to major design projects, I regularly take on smaller, fast-paced mechanical design and fabrication tasks to support cross-functional teams. These tasks range from quick part modifications and in-house machining to designing and delivering functional tools or fixtures for R&D, quality, and production use.

Examples of these hands-on projects include:

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• Catalyst Coating Fixture: Designed and built a custom fixture to assist the R&D team in applying catalyst layers onto electrodes with improved precision and repeatability.
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• Hydraulic Lifting Cart Modification: Customized a heavy-duty cart to safely transport sub-scale electrolyzer stacks weighing up to 500 pounds.
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• Inspection Fixture: Created a hybrid laser-cut and 3D printed fixture for the quality team to streamline and standardize part inspection for incoming components.