Design / Manufacturing / Prototyping
My experience spans metal additive manufacturing at Sig Sauer, aftermarket sustainment engineering at Pratt & Whitney, and medical-device development at Pirouette Medical. I work across CAD, fixtures, process documentation, and hands-on production to support hardware from design through manufacturing.
2025 to 2022
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Repair / Machine recommissioning
Corroded sealing faces on a used machine, rebuilt flat in-house against a months-long lead time.
View the design process
Design study / Reverse engineering
From a scanned accessory connection to a custom, wall-mountable dock.
View the design processOne-off parts and small repairs.
In my Accord I wired a four-channel amp for the door speakers and a mono amp for the sub. When the connections in the Rockford Fosgate amp stopped working, I took it apart and cleaned it inside, and it worked fine afterward. The headliner was sagging, so I took it out, wire-brushed off the gooey residue the old material left behind, and covered it in new suede.
The bed level sensors failed, so the printer stopped getting a probe measurement and kept driving the head into the plate. I stripped it down, cleaned the boards and connections, and retightened the belts. Reinstalling the pressure sensors was the real problem: with no factory torque spec I could not reproduce the original preload, so rather than guess I ran a system recalibration and let the machine re-zero against the torque I had actually applied. It has printed correctly since.
I found a filament holder design online, liked the idea, and modelled my own rather than printing theirs. The original was built around 28 mm timber, which is not a size a US hardware store sells, so the bracket had to be sized around dowels I could actually buy. A small printed collar checked the dowel fit before I committed to a pair of brackets.
I studied engineering at Embry-Riddle and the University of Central Florida, and I'm finishing my bachelor's degree part time. I'm most drawn to aviation and aircraft, and to work that takes a part from a CAD model to something I can hold.
About Zachary