I build products from first prototype to production. I lead process R&D, turn messy physics into manufacturable systems, and translate complex problems into clear decisions for teams and leaders. Currently developing volumetric additive manufacturing at Georgia Tech; previously process R&D and leadership at Formlabs.
NSF GRFP FellowGeorgia Tech PhDFormlabs R&D
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02
Experience
View Details
2019 - 2023
Formlabs
Senior R&D Engineer & Tech Lead
SLSOpticsThermal
03
Research
PhD Research
Radio Frequency Additive Manufacturing
Volumetric polymer sintering via RF energy delivery—10x speed potential, infinite recyclability, and novel material modalities
10xSpeed Potential
600W13.56 MHz
Explore Project →
Diagnostics
Scanner-Based Metrology
$100 flatbed scanner + Python/OpenCV for dimensional jetting diagnostics
Learn More →
Publications
Research Output
2 SFF Conference Papers
npj Advanced Manufacturing
AM Letters (submitted)
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04
Archive
Featured on Hackaday
Over-Engineered Bottle Opener
A ridiculously over-engineered automatic bottle opener built in college—featured on Hackaday article and podcast
Watch the Video →
Industrial Design
Temporal Rift
An interactive installation where guests peer through an interdimensional portal to view AI-generated alternate realities of Georgia Tech
View Installation →
Industrial Design
Orbit
A mobile app helping seniors plan weekly activities to stay active, mobile, and socially connected
10+ years studying and performing jazz. Lead alto in NIU Jazz Orchestra. Music taught me to listen, collaborate, and improvise—skills that translate directly to engineering.
Louis Armstrong AwardNIU Music ScholarPurdue Jazz Winner
More About Music →
Let's Connect
Interested in working together?
I'm always open to discussing additive manufacturing, research collaborations, or industry opportunities.
At Formlabs, I worked on the Fuse series of SLS 3D printers, progressing from intern to Tech Lead. I owned thermal and optical subsystems, managed cross-functional programs, and authored 30+ technical reports that enabled data-driven engineering decisions. The calibration tools and process characterization systems I developed are actively deployed across tens of thousands of Fuse printers today—including notable makers like Adam Savage.
30+Technical reports authored
3xDimensional accuracy improvement
120WNext-gen laser characterization
Featured: Bed Temperature Fine Tuning Tool
My most widely deployed tool—used by customers, field engineers, and makers like Adam Savage. Diagnostic part with torque spinners, dimpling grids, and birchbark cones for visual/mechanical assessment of thermal uniformity.
Diagnostic Tool
Adam Savage's Setup
Left: Adam Savage's Fuse 1+ 30W (tool at 7:42) • Right: Official Formlabs tutorial
Featured: Fuse 1+ 30W Technical Program Management
Despite its "plus" naming, the Fuse 1+ 30W was a complete rebuild of Formlabs' SLS platform—new optical systems, thermal systems, material handling, PCBAs, electronics, and software. I served as Technical Program Manager from EVT through production launch, coordinating 30+ engineers across 130+ ECOs to deliver the program in just 9 months—the fastest full printer launch in Formlabs history.
EVT Bringup
DVT Bringup
Program leadership:
Cross-functional coordination: Owned the engineering program schedule, tracked dependencies across ME, EE, firmware, and software teams. Ran daily syncs to identify blockers and ensure tasks were completed on time
In-house EVT builds: Coordinated with manufacturing, global sourcing, and the 30+ engineers owning the 130+ ECOs required for this "incremental" update that was actually a ground-up redesign
Go/no-go decisions: Partnered with the Operational Program Manager to host go/no-go meetings. I owned engineering readiness while translating executive and marketing timelines into achievable engineering milestones
Factory & production:
Factory test software: Managed the factory software team responsible for the 150+ tests each printer must pass. Owned test design, implementation, and validation—ensuring every unit met spec before shipping
Production deployment: Worked closely with the factory through daily calls, serving as the point person for test validation and build quality. Led the rollout for months into the production phase
Release authority: Served as the central decision-maker for production release—determining when printers were ready to ship to customers
Impact:
The Fuse 1+ 30W remains Formlabs' flagship SLS printer and holds the largest SLS market share by units sold
Recognized as one of the best SLS printers on the market for print quality, speed, and cost—priced below most competitors
Now a major and growing segment of Formlabs' revenue
Additional research enabling data-driven decisions for next-generation SLS development:
XY Scaling Calibration System
LEGO approached us with a challenge: if we could achieve sub-100μm tolerance, they would equip their facilities with multiple Fuse printers. I developed a per-printer calibration tool using Gage R&R methodology and Outer Boundary Offset correction for thermal bleed, improving factory standard performance by 3x to achieve ±100μm tolerance. This enabled LEGO to deploy Fuse printers in their production lines—not just for jigs and fixtures, but for end-use pieces as well.
Increased print speed 30% via thermal optimization. Achieved 33% interlayer time improvement, yielding approximately 4 hours of free build time per print job.
Print speed comparison: before and after thermal optimization
120W Laser Characterization
Systematic study of high-power lasers (30W-120W). Introduced peak irradiance as key metric and recommended 70W/500μm as optimal configuration.
Thermal Uniformity Study
Correlated bed temperature distribution with part quality. Found thermal uniformity drives elongation at break (6% center vs 4% edges).
Variable Focus / Large Spot
Proved 800μm spot feasibility via Central Composite Design. Achieved 40% Z-EAB improvement and ~10% speed gain.
Minimum Power Density Study
Challenged industry assumption of 104 W/cm² threshold. Proved Nylon 12 prints at 336 W/cm² (30x lower), validating VCSEL array feasibility.
Senior Optical & Thermal Systems Engineer
Tech Lead
April 2023 - September 2023
Owned thermal and optical subsystem development for next-generation SLS platforms
Translated process physics into requirements, verification plans, and design trade studies
Developed multi-laser optics concepts (beam shaping, variable focus, scan strategies)
Created predictive frameworks: peak irradiance process maps, print time models, cost-performance optimization
Hiring manager: hired multiple full-time R&D engineers and dozens of interns
Print Process Engineer & TPM
Fuse 1+ 30W
May 2021 - April 2023
TPM responsibilities detailed in featured section above.
Print Process Engineering:
Increased print speed 30% via thermal optimization; 33% interlayer improvement yielded ~4hr free build time
Reduced fleet dimensional error from ±300μm to ±100μm on critical features
Designed closed-loop nitrogen inerting system; reduced gas consumption 60%
Designed factory calibration systems scaled to thousands of production units
Mechanical Engineering Intern
May 2019 - September 2019
Improved printed geometry accuracy by 25% on pre-launch Fuse SLS
Discovered and resolved laser transposition issue in beta units
Advancing Volumetric Additive Manufacturing via Radio Frequency Energy Delivery
Georgia Tech • Digital Design & Manufacturing Lab
RFAM is a novel volumetric approach combining layerwise dopant deposition with volumetric RF heating to sinter polymers. Carbon/graphite-doped nylon powder is exposed to an RF field between copper electrode plates—the dopant selectively absorbs RF energy, generating heat that melts the surrounding nylon, enabling particle coalescence and part densification. Unlike laser sintering that scans sequentially, RFAM heats the entire build volume simultaneously—enabling order-of-magnitude improvements in speed, energy efficiency, and material utilization.
Custom Faraday cage with parallel copper electrodes and motorized turntable for isotropic field exposure
RF-transparent build chambers (PLA/nylon) with compliant printed spring sealing systems
Custom high-loading graphite inks (up to 25 wt%) developed with Nazdar
Advisors
Dr. Carolyn C. Seepersad (Woodruff Professor) & Dr. Christopher J. Saldaña (Ring Family Professor)
Additive ManufacturingRF HeatingBinder JettingPolymer SinteringCOMSOL MultiphysicsProcess Development
Research Project
Low-Cost Scanner-Based Diagnostic Pipeline
Dimensional Metrology of Jetting Fidelity in Binder Jet AM
A low-cost, scanner-based diagnostic pipeline for quantitative dimensional metrology of jetting outcomes in binder jet additive manufacturing (BJAM). The approach combines high-resolution flatbed scanning (4800–9600 dpi, ~5.3 μm pixel pitch) with open-source Python/OpenCV computer vision to extract feature-specific metrics, producing standardized aggregate and per-instance data products suitable for iterative calibration.
~$100Total system cost
$50-100KSystems it replaces
4800 dpi5.3 μm pixel pitch
Diagnostic Pipeline Workflow
Two Diagnostic Capabilities
This tool serves two complementary functions for RFAM process validation:
Dimensional Accuracy: Evaluates jetting fidelity and compensates for system-level mechanical errors (scale, yaw, backlash)
Carbon Concentration Classification: Classifies ink concentration levels to verify dopant distribution for RF heating uniformity
Dimensional Accuracy Analysis
Calibration patterns are printed on low-wicking substrates to preserve precise droplet locations, then scanned and analyzed to extract geometric error metrics.
Pitch rulers: Minimum resolvable bar width as a function of sampling resolution
Carbon Concentration Classification
For dopant concentration analysis, chromatography or blotting paper substrates are used due to their ability to absorb and spread droplets into consistent, analyzable halos. Grayscale intensity values are sampled from doped regions and mapped to dopant concentration using calibration curves developed from manual ink deposition of known volumes and carbon content.
The classifier uses multiple estimation methods (weighted score, k-NN, logistic regression, concentration-by-skewness) to determine carbon loading from scanned inkblot patterns. This enables verification that the correct dopant concentration is being deposited across the powder bed—critical for achieving uniform RF heating during sintering.
Classifier Workflow
Inkblot Heatmap Analysis
Key Contributions
Digital "gold-standard" validation isolates algorithmic behavior from physical printing variability
Design of a Modular, Scalable Open-Architecture Platform for Binder and Material Jetting Additive Manufacturing
A Low-Cost Scanner-Based Diagnostic Pipeline for Jetting Fidelity and Dopant Distribution in Binder Jet Additive Manufacturing
Physical Pathways for Compensating Shrinkage and Field Nonuniformity in Radio Frequency-Driven Additive Manufacturing
Model-Informed Input Design for Radio Frequency–Driven Additive Manufacturing: Functional Grading and Inverse Lithography-Inspired Pre-Distortion
Radio Frequency as a Volumetric Energy Paradigm for Additive Manufacturing: Principles, Modalities, and Opportunities
Patents & Disclosures
Patent contributions/invention disclosures at Formlabs (SLS systems and processes)
Featured on Hackaday
Over-Engineered Bottle Opener
2020
Sometimes the best engineering projects are the ones that solve problems nobody asked to be solved. This ridiculously over-engineered automatic bottle opener was built with friends during college—and ended up getting featured on Hackaday's website and podcast.
100thHackaday Podcast Episode*
100%Over-Engineered
0Problems Actually Solved
*Listed as #99 because Hackaday uses zero-indexed episode numbering
Temporal Rift is an interactive installation created for Georgia Tech's biannual student showcase. Guests could peer through an interdimensional portal to view alternate realities of the Georgia Tech campus, using physical controls to navigate between worlds and locations.
Concept
The installation simulates an interdimensional portal that has "ripped" through a wall, revealing glimpses of alternate futures. Guests can use two physical dials to control the experience: one selects the alternate world, and one selects the campus location they're viewing. Five distinct worlds were created, each with three campus locations (15 total scenes):
Digital World (2092) - A cyberpunk future with neon-lit holographic interfaces
Green World (2075) - Nature has reclaimed the campus with overgrown vegetation
Outer Space (2524) - Georgia Tech as an interstellar space station
AI Takeover (2148) - Robots and AI have transformed the campus
Underwater (2262) - The campus submerged in an underwater city
Installation Videos
World Navigation Demo
Installation Demo
Process & Exhibition
Installation Overview
Control Panel
Portal Frame
World Selection
Guest Interaction
Alternate Reality
Physical Installation
Exhibition Setup
AI-Generated Content
Final Exhibition
Technical Implementation
Hardware: Arduino-controlled rotary encoders and physical dial controls
Software: TouchDesigner for real-time video playback and UI feedback
Content: AI-generated video content using Runway, with post-production in After Effects and Premiere Pro
Physical Design: Drywall wall construction with sculpted foam "broken wall" effect and rear projection surface
My Contributions
Concept development and world design
Hardware design (Arduino, control panel, wiring)
TouchDesigner programming and UI design
Physical installation construction
Content generation (shared with collaborator)
Collaborator
Jojo Brauer
TouchDesignerArduinoRunway AIAfter EffectsPremiere ProPhysical ComputingInstallation Art
Service Design
Orbit
Service Design, Brand & Marketing • Fall 2025
Orbit is a mobile app designed to help seniors plan weekly activities that keep them physically active, mobile, and socially connected. Developed through user research with elderly community members and healthcare workers, the app addresses the growing need for tools that support healthy aging while respecting independence and autonomy.
The Problem
As populations age globally, many seniors face challenges staying physically and socially active. Research shows that maintaining regular activity is crucial for both physical health and mental wellbeing, yet many older adults struggle to find and plan appropriate activities that match their preferences, abilities, and social needs.
Interactive Prototype
Click through the app to experience the onboarding flow and main features.
Key Features
Personalized Onboarding: Questions about activity preferences, social styles, travel willingness, and schedule to tailor recommendations
Weekly Activity Planning: Calendar-based interface for scheduling activities throughout the week
Social Connection: Features to coordinate activities with friends and meet new people with similar interests
Organizer Portal: Separate flow for activity providers to list and manage events
Accessibility Focus: Large text, simple navigation, and clear visual hierarchy designed for older adults
Design Process
Conducted interviews with elderly community members and healthcare workers
Created journey maps and service blueprints to identify pain points
Developed personas based on research findings
Iterative prototyping with user feedback
Built working prototype using Figma and React
My Contributions
User research and stakeholder interviews
Wireframing and UI/UX design
Interactive prototype development
Service blueprint creation
Team
Victoria Gamez (MID), Michelle Kim (MID), Matt McCoy (ME PhD)
Service DesignUX ResearchFigmaReactPrototypingAccessibilityHealthcare
Beyond Engineering
Jazz Saxophone
10+ Years of Performance & Study
I studied Jazz Saxophone Performance at Northern Illinois University, playing lead alto in the NIU Jazz Orchestra and Ensemble under the direction of Geof Bradfield, Reggie Thomas, and Rich Moore.
Music taught me to listen deeply, collaborate effectively, and think on my feet—skills that translate directly to engineering leadership and research.
