> Diagnosed an operator-dependent thermal testing pipeline that burned ∼20 weeks/year waiting for unusable data.
> Rebuilt the IR hotspot detection system to make tests repeatable and operator-independent by upgrading the IR camera, redesigning the internal chamber and camera mount for fixed positioning, and consolidating the sensor and motor electronics into a single enclosure.
> Designed and validated a repeatable dip coating system for PCTFE parts (surface prep, paint selection, and dip parameters via
DOE) to replace manual airbrushing; cut hands-on processing time by 95% while holding coating thickness within ±0.05 mm.
> Designed modular thermal validation fixtures and a redesigned saline containment lid, streamlining fixture setup and improving evaporation resistance in initial testing.