PORTFOLIO

Regeneron

iRobot

Hologic

Classes

Regeneron Pharmaceuticals

Regeneron

Syringe Needle Study: [Testing/Analysis]

I had the opportunity to work on a project characterizing forces and image data and angles for fluid from a needle.

Problem: The auto-injector devices used for dispense of drug product included a syringe component. The properties of uncapped syringe needles were being investigated for a drug product.

Action: Designed and ran test method to determine impact

tested over 100+ samples
experiment spanned 24 hrs at various timepoints
designed test fixture for Cognex camera Instron attachment in Solidworks and 3D printed with Connex
refined and developed detailed timing instructions for test method to ensure all samples tested at correct time
analyzed images with ImageJ to determine stream angles
ran minitab statistics on data to draw correlations/regressions, plot box plots and understand significance of results
presented results internally to full medical device group

Results: Drew conclusions on impact of uncapped syringes

test method developed to be utilized in future
potential impact on patient usage instructions

Images of uncapped syringe needles (pics taken in lab with toolmaker microscope)

Cognex camera / Instron Tensile Tester Needle test setup developed

Example "break-loose, glide-force" load profile collected from Instron

above: 1000X magnification of the sample using SEM

above: 2000x magnification of filter

left: non-magnified sputter-coated filter sample

Scanning Electron Microscope (SEM)

Filter Investigation [Testing/Analysis]

Problem: Filter pore size was assumed to match manufacturer specifications; a test of the actual pore size could help identify any potential causes of early filter clogging.

Action: Designed and ran test method using SEM

wrote SEM test method protocol
used 3 samples each from 4 different filter variations
sputter coated and prepared all filter piece samples
collected image data from SEM magnification
used imageJ to measure the pore sizes; averaged results for indication of average size pore size per filter
ran EDX (energy-dispersive x-ray) analysis with SEM to gather material / element composition data

Results: Drew conclusions on variability and pore size

no unexpected bioburden elements found through EDX
results to be used / compared against manufacturer specs

iRobot

Gasket Geometry Prototype: [Design]

Problem: Manufacture of gaskets wastes a lot of material; a method of reducing the material needed to die-cut geometry out could save on costs.

Action: Designed prototype concepts for reducing material

researched existing /prior patents on space minimization
experimented with different geometries using simple paper prototypes to fold out from smaller footprint
identified most promising designs and modeled in PTC (Pro-E) Creo CAD program
created drawing PDF and converted to Corel file
laser cut prototypes out of various foams (adjusted the power and speed settings to identify optimal settings for the material)
shared findings with team engineers

Results: Functional prototype of redesigned gasket

80 % less material used with new design
to be considered for potential manufacture implementation

above: gif of gasket unfolding

above: design when initially cut out

below: design when folded out into actual usage form

above: side view CAD for padding design

below: carrier prototype

Carrier for Large Robot: [Design]

Problem: large, heavy, bulky robots can be hard to carry to field tests and events; having a dedicated carrier to make this process easier while protecting the robot would be beneficial.

Action: Designed and prototyped carrier device

measured and CAD-modelled shape of the robot itself
designed carrier through modification of an existing cart design to include cushioning and attachment points
prototyped the carrier
made modifications based on dimensions, fit and hole spaing requirements to support load
developed CAD PDF drawings to be sent to machine shop for metal prototype

Results: Prototype and CAD model/drawings

prototype serves as proof of concepts for design
next steps: machining of parts

Hologic

Test Bed for Store Display Testing [Design/Testing]

Problem: testing required to ensure that store display units would showcase correct behaviors

Action: Built test bed and tested robot

planned test bed design based on marketing mockups of actual display designs
ordered wood and constructed test bed for robot, included easily configurable middle divider to test different sizes
tested and videotaped robot behavior during normal run
identified issues with certain configurations of test bed and materials used
communicated issues with product manager and worked with engineers to resolve

Results: built and tested display

identified potential issues to be resolved before sending
test beds displayed in almost 300 Best Buy stores nationwide during Roomba 980 launch

above: test bed created and used for testing. below: actual public Best Buy store display.

Hologic Inc.

above: CAD for fixture plate redesign

where the holes are dimensioned to fit the Instron plate for consistent mounting

Instron Force Testing [Design/Testing/Analysis]

Problem: Disposable components were being tested to ensure they met requirements for pull force specifications.

Action: Ran test, modified fixture, suggested improvements

tested over 30+ samples
ran Instron method for tension and compression tests
analyzed data with minitab to determine if normal data set
modified test fixture model with Soliworks to reduce variation in Instron base plate attachment in order to reduce operator variation during testing
created drawing for machining of revised parts
designed grip modifications to increase ease of user pull in case higher forces unavoidable

Portfolio

Regeneron Pharmaceuticals

Syringe Needle Study: [Testing/Analysis]

I had the opportunity to work on a project characterizing forces and image data and angles for fluid from a needle.

​

Problem: The auto-injector devices used for dispense of drug product included a syringe component. The properties of uncapped syringe needles were being investigated for a drug product.

​

Action: Designed and ran test method to determine impact

tested over 100+ samples

experiment spanned 24 hrs at various timepoints

designed test fixture for Cognex camera Instron attachment in Solidworks and 3D printed with Connex

refined and developed detailed timing instructions for test method to ensure all samples tested at correct time

analyzed images with ImageJ to determine stream angles

ran minitab statistics on data to draw correlations/regressions, plot box plots and understand significance of results

presented results internally to full medical device group

​

Results: Drew conclusions on impact of uncapped syringes

test method developed to be utilized in future

potential impact on patient usage instructions

Images of uncapped syringe needles (pics taken in lab with toolmaker microscope)

Cognex camera / Instron Tensile Tester Needle test setup developed

Example "break-loose, glide-force" load profile collected from Instron

above: 1000X magnification of the sample using SEM

above: 2000x magnification of filter

​

left: non-magnified sputter-coated filter sample

Scanning Electron Microscope (SEM)

Filter Investigation [Testing/Analysis]

​

Problem: Filter pore size was assumed to match manufacturer specifications; a test of the actual pore size could help identify any potential causes of early filter clogging.

​

Action: Designed and ran test method using SEM

wrote SEM test method protocol

used 3 samples each from 4 different filter variations

sputter coated and prepared all filter piece samples

collected image data from SEM magnification

used imageJ to measure the pore sizes; averaged results for indication of average size pore size per filter

ran EDX (energy-dispersive x-ray) analysis with SEM to gather material / element composition data

​

Results: Drew conclusions on variability and pore size

no unexpected bioburden elements found through EDX

results to be used / compared against manufacturer specs

iRobot

Gasket Geometry Prototype: [Design]

​

Problem: Manufacture of gaskets wastes a lot of material; a method of reducing the material needed to die-cut geometry out could save on costs.

​

Action: Designed prototype concepts for reducing material

researched existing /prior patents on space minimization

experimented with different geometries using simple paper prototypes to fold out from smaller footprint

identified most promising designs and modeled in PTC (Pro-E) Creo CAD program

created drawing PDF and converted to Corel file

laser cut prototypes out of various foams (adjusted the power and speed settings to identify optimal settings for the material)

shared findings with team engineers

​

Results: Functional prototype of redesigned gasket

80 % less material used with new design

to be considered for potential manufacture implementation

above: gif of gasket unfolding

above: design when initially cut out

below: design when folded out into actual usage form

above: side view CAD for padding design

below: carrier prototype

Carrier for Large Robot: [Design]

​

Problem: large, heavy, bulky robots can be hard to carry to field tests and events; having a dedicated carrier to make this process easier while protecting the robot would be beneficial.

​

Action: Designed and prototyped carrier device

measured and CAD-modelled shape of the robot itself

designed carrier through modification of an existing cart design to include cushioning and attachment points

prototyped the carrier

made modifications based on dimensions, fit and hole spaing requirements to support load

developed CAD PDF drawings to be sent to machine shop for metal prototype

​

Results: Prototype and CAD model/drawings

prototype serves as proof of concepts for design

next steps: machining of parts

Test Bed for Store Display Testing [Design/Testing]

​

Problem: testing required to ensure that store display units would showcase correct behaviors