Tesla — Optimus

Assembly and sensor work on Optimus. Designed a pneumatic machine to automate glove installation — 10× faster than the manual process. Rebuilt the sole bonding process from scratch: 2× joint strength, 75% less cycle time. Built an automated tactile validation station that cut end-of-line test time by 21×. Wrote Python and MATLAB pipelines for live sensor data off the robot, enabling automated health checks. On the DFM side, cut 24 parts from arm assemblies and pushed structure sensor bonding yield from 60% to 100%.

Kinetic Materials Research Lab — UIUC / DARPA

Built a high-resolution 4-axis 3D printer from scratch for embedded additive manufacturing at micro and nano scales. Interfaced with ACS Motion Control hardware, wrote MATLAB toolpath and G-code generation, and designed a 9-nozzle manifold that increased throughput 9×. Full 0 → 1 build.

Procter & Gamble

Built and statistically validated high-throughput testing rigs using UR collaborative robots, calibrated against observed consumer behavior. DFM work increased production speed by 120%. Built JMP statistical models to translate consumer data into product design guidelines.

Schneider Electric

Led a Lean Six Sigma project on procurement and resource allocation. Root-caused systemic delays averaging three months per delivery cycle and drove the fix through implementation.

Illini Formula Electric — UIUC

Redesigned the suspension-chassis joint for the electric formula car — 15% weight reduction, half the manufacturing time, easier to service. Ran ANSYS FEA on drivetrain and brake components.

EgyptAir

Non-destructive testing on steel and composite aircraft structures using Eddy Current, Ultrasonic, and Thermal Imaging. Manufacturing of composite and non-composite replacement components for certified aircraft.

University of Illinois at Urbana-Champaign

Focused on hardware design and control systems. Most of the real work happened in the research lab and on the Formula Electric team.