Selected Work
A selection of engagements across PCBA manufacturing, DFM review, web design, and product development. Details adjusted where NDA applies.
A tier-1 avionics manufacturer experiencing elevated IPC-A-610 reject rates engaged me to perform a full SMT line audit. The engagement covered stencil printer setup, paste inspection thresholds, reflow profile validation across three oven zones, and Fuji NXT feeder management. Process SOPs were rewritten from scratch to reflect actual line configuration.
Pre-production Gerber review for a ruggedized defense board with multiple high-density BGAs. Identified via-in-pad escape routing issues, stencil aperture area ratio failures for fine-pitch components, and thermal relief inadequacies near a large copper pour.
A full-stack web application built for a youth soccer coaching program. The platform provides coaches and players with role-based dashboards, structured training plan management, and a drill library. Built with Next.js and Supabase, deployed on Vercel with automatic CI/CD — replacing scattered PDF handouts and group chats with a single organized platform.
Features include role-based access control, auto badge award system, training plan builder, user onboarding guides, and Venmo deep link integration.
Consulted on a high-volume consumer electronics line experiencing intermittent solder bridge defects on a fine-pitch QFP. Root-caused to stencil wear and aperture expansion over time. Implemented incoming stencil inspection criteria and replacement schedule.
Designed and printed a custom NACS adapter cradle to replace a J1772 holster on a commercial EV charging station. Iterated through geometry challenges for fit, retention force, and UV-resistance requirements. Multi-color print with snap-fit retention.
Developed a comprehensive X-ray inspection SOP for a Creative Electron TruView Novus system for use on avionics assemblies. Covered image acquisition parameters, void acceptance criteria per IPC-7095, BGA cross-section interpretation, and non-conformance documentation workflow.
Full rebuild of a regional table tennis league management platform. Features ladder rankings, match result entry, badge award system, and player profiles. Built on React with Supabase backend and deployed on Vercel with automatic CI/CD.
Converted a Meshy.ai-generated 3D model to a multi-color Bambu Lab 3MF print using a custom Python GLB-to-3MF conversion script with per-face color assignment. Listed on PVEPrintShop Etsy storefront as a repeatable product.
Developed a repair and touch-up SOP for Parylene C removal and Arathane 5750 recoating on flight-heritage avionics assemblies using the Comco AccuFlo AF10 system. Covered blast media selection, masking procedures, cure verification, and IPC-CC-830 acceptance criteria.
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