During a project at Bose, I was tasked with identifying the most effective adhesive for bonding dissimilar materials—specifically ABS plastic and 410 stainless steel (410SS). The ABS components were injection molded, and the 410SS parts were machined to simulated an idealized assembly environment. I was responsible for designing, quoting, and sourcing all sample components.

Each selected adhesive was applied to a fixed number of sample pairs, which were allowed to fully cure prior to testing. For tear testing, samples were placed into the test rig shown on the right, where a force sensor measured the maximum load required to separate the bonded parts. Below is a comparison of the samples before and after testing.

As part of a Bose project, I was tasked with developing a waterproof button solution for a product mounted on the arm of a pair of glasses—making waterproofing a critical design requirement.

To explore viable solutions I conducted a product teardown of a waterproof smartwatch, focusing on its side button mechanism.

This fixture was designed for an Axon dashboard-mounted camera product. The goal was to simulate a real-world scenario in which a police officer must quickly press a button on their dashcam in response to an urgent situation, before continuning with their task.

The primary objective of the test was to determine the range of force a user might apply when interacting with the button under stress or time-sensitive conditions, helping to inform appropriate force thresholds for final button design.

As part of an Axon project, I was tasked with developing a compact sheet metal component concept that met the following requirements:

• Capable of carrying a crimped-on component

• Electrically conductive

• Able to penetrate through corrosion

• Small form factor

The component was designed with deep draw manufacturing in mind, measuring 12.3mm in length and 8mm in diameter. Prototypes were produced due to the project being put on hold until a follow-on contract was awarded.

As part of an NFL-related project, we needed to simulate helmet-to-helmet collisions in order to test adhesion options—without modifying the helmets themselves, as per manufacturer restrictions.

To replicate impact conditions, we constructed a custom drop test tower capable of simulating collision speeds up to 100mph from top to base. The tower was built from wood and featured a simple pulley system anchored to the wall using concrete bolts. Additional support stands were added to minimize sway from wind or vibration during testing.