Scope
Led end-to-end development of a next-generation professional power tool within Milwaukee Tool`s New Product Development Group as a Mechanical Design Engineer. Owned product execution from concept through mass production, coordinating cross-functional efforts across Electrical, Motor, Reliability, Manufacturing, and Product Marketing teams to deliver a solution aligned directly with customer requirements and field use cases.
Design/Prototyping
Developed full-system 3D CAD models in Siemens NX, managing product data through Teamcenter. Leveraged rapid prototyping (polymer and metal additive manufacturing) to validate form, function, and assembly feasibility early in development.
Conducted on-site field feedback sessions at professional job sites to identify edge cases and real-world usage patterns, directly informing CTQ requirements and design validation criteria.
Analysis
Led structural and dynamic FEA using ANSYS Static Structural and LS-Dyna to validate core mechanism durability and impact performance.
Owned drop simulation strategy, eliminating all drop-test failures between first and second prototype builds - significantly reducing physical iteration cycles and development risk.
Performed 200+ tolerance stack-up analyses in both Excel and Enventive to ensure robust product performance across manufacturing variation.
Manufacturing
Partnered with global engineering and supplier teams to implement DFM improvements across injection molding, powder metal, metal injection molding, investment casting, and machined components.
Produced GD&T-compliant technical drawings and collaborated directly with suppliers to refine measurement strategies and achieve mass-production capability without compromising design intent.
Testing/Root Cause Analysis
Developed accelerated life-testing methodologies to reduce validation time while maintaining reliability targets.
Applied high-speed video analysis to diagnose dynamic phenomena not observable through conventional inspection methods.
Led structured failure analysis investigations and standardized DOE-based test procedures to improve comparative validation across configuration variants.
Summary
This experience provided full lifecycle ownership of professional-grade hardware development - integrating design, simulation, manufacturing, and validation into a cohesive execution strategy focused on performance, manufacturability, and customer impact.