May 2023 – Present · San Diego, CA
ATHLETE
MANAGEMENT
TECHNOLOGIES

Lead Mechanical Engineer — running 6+ concurrent hardware programs while also operating as the company's hands-on fabrication, prototyping, and 3D printing operation. I'm not just designing — I'm building.

Role
Lead Mechanical Engineer
Location
San Diego, CA
Programs
6+ Concurrent
Stage
Startup / Full Ownership
6+
Concurrent Hardware Programs
90%+
Less Manufacturing Time on Outsourced Parts
~30%
Charging Efficiency Gain
70%+
Less Heat Under Full Load
"At a startup, there's no department to hand things off to. I own the design, the prototyping, the testing, the iteration, the production drawings, and the 3D printing operation — all of it, simultaneously. That's not a burden. That's how I prefer to work."
Scope of Work
WHAT I ACTUALLY DO HERE
📐
Mechanical Design & CAD
Create detailed CAD models and engineering drawings for all hardware programs. Develop system architecture and packaging solutions that balance performance, durability, manufacturability, and reliability — all at the same time.
🖨️
3D Printing Operations
Run the company's entire additive manufacturing operation. Managing FDM and resin printers (Bambu Lab, Mingda, Formlabs) across multiple programs simultaneously — material selection, print settings, post-processing, and quality control.
🔬
Analysis & Simulation
Perform structural and thermal analysis using first principles and simulation tools to evaluate designs and guide engineering decisions before cutting hardware. FEA-driven iteration to get to the right answer faster.
🧪
Test & Validation
Execute validation testing, collect and analyze performance data, and perform root cause failure analysis to drive design improvements. Closed the loop between simulation and hardware reality.
⚡
Electronics Integration
Integrate sensors, electronics, and mechanical components into testable assemblies. Hands-on soldering, electromechanical assembly, and troubleshooting of embedded hardware systems.
🏭
Production Scaling
Design for manufacturability (DFM) and assembly (DFA) from day one. GD&T on all drawings. Support the transition from prototype to production release — including supplier communication and production documentation.
Fabrication
THE 3D PRINTING OPERATION

I run the full additive manufacturing operation for AMT — from selecting the right process and material for each application, to managing print queues across multiple machines, to post-processing and quality inspection.

This means knowing when to use FDM vs. resin, which materials hold up under vibration or heat, how to orient parts for strength, and how to design features that actually print reliably — not just look good in CAD.

The 20-unit charger took 20 iterations; the more complex 40-unit charger took 9. The printing operation is a core part of what makes the development cycle fast. When I can turn around a new iteration same-day, the whole program moves faster.

Materials I regularly work with: PLA, PETG, ABS, ASA, TPU, engineering-grade nylons, and photopolymer resins for precision components.

Machines in Operation
🖨️
Bambu Lab
FDM · High-speed multi-material, functional prototypes
🖨️
Mingda
FDM · Large-format parts, structural components
🔬
Formlabs
Resin (SLA) · High-detail, precision enclosures & parts
Why this matters
Most engineers rely on a separate fab team for prototypes. I close that loop myself — designing, printing, testing, and iterating without handoff delays. That loop is how the iteration count dropped from 20 to 9.
Active Work
HARDWARE PROGRAMS
01
Wearable Sensor Systems
Ruggedized enclosures for athlete-worn sensor hardware. Designed for durability, field serviceability, and real-world abuse. Extensive vibration and impact testing. Thermal and moisture management integrated into packaging design.
Ruggedized Design Electronics Packaging Thermal Management DFM
02
Multi-Unit Charging Systems
Scalable charging infrastructure for multi-device fleets. Focus on thermal performance under sustained load, production-ready design, and field reliability. Designed for volume manufacturability from the first iteration.
Thermal Design Manufacturability Power Systems Production Scaling
03+
Additional Concurrent Programs
Managing 3+ additional active hardware programs simultaneously — each at different stages of the development lifecycle. System architecture, packaging design, prototyping, and test execution running in parallel across the portfolio.
Parallel Execution Program Management Cross-Program Reuse