Aidan Dunne

• Designed, modeled, fabricated, assembled, and tested a smart kingpin for Range Energy's flatbed trailer. • Learned CATIA and improved on finite element analysis (FEA) skills in order to model the kingpin based on predefined requirements. • Designed the kingpin to accurately sense up to 50kN and withstand a one-time max load (crash scenario) of 420kN in the x-y direction. I used hand calcs & FEA to ensure the part had enough measurable strain while being structurally sound. • Improved fabrication skills using the mill, lathe, TIG/MIG welding, plasma cutter, 3D printing, and powder coating • Scheduled and assisted in supplier meetings to receive needed parts by preset deadlines.

• Stator design & geometry optimization to minimize end effects and reduce magnetic saturation for a linear induction motor on Hyperloop competition pod. • Lead a portion of the propulsion team to integrate a pipe jacking method of propulsion into a competition tunnel boring machine.

Designed and built an automatic modular pressure test fixture for a consumable device. The fixture pressurizes a given system up to a specified pressure within 0 to 100 psi, monitors and records the internal leak rate of the system, and brings it back down to the system's original pressure. Created a list of requirements, specified a part list, and modeled an assembly of the pressure tester SolidWorks. Assembled the pressure test fixture from parts that were ordered, laser cut, and 3-D printed. Characterized the system throughout the assembly process to ensure that all parts performed well with respect to the requirements document. Worked closely with a software engineer to integrate Ubuntu with a single board computer (SBC) and program the system to take the user's inputs and perform as required. Gained experience with electromechanical interfaces such as SBCs, PWM boards, DIN-rail power supplies, terminal blocks, solenoid valves, electric pressure regulators, and diaphragm/syringe pumps. Also gained experience working with McMaster Carr and IDEX parts to assist with fluidic connections. Lastly, gained experience synthesizing my work and presenting weekly updates to my team, as well as organizing intern events outside of work.

Assembled and tested prototypes of an electromechanical eyedropper. I assembled the core of the eye dropper using custom 3D-printed parts, cyanoacrylate, UV adhesive, and springs. After building each unit I performed internal tests to make sure the system had no leaks and maintained a constant pressure over time. I later performed reliability and compatibility tests to make sure the design was durable and maintained performance with different drugs. I presented struggles, findings, and future plans to my team on a weakly basis. On the side I designed and 3D printed fixtures to assist with testing so measurements were more reliable. For example, I designed a special mount for a force gauge and a holder for the eyedropper core to be used during assembly.

Completed summer internship at GALT, a small start up that designs and builds electromechanical equipment to isolate microbes from complex microbiome samples. Applications include microbiome based therapeutics for human and animal health as well as sustainable alternatives to pesticides in agricultural food productions. During my internship, I had a project to minimize evaporation from nanoliter sized wells. I planned, organized and executed testing of different adhesive seals to evaluate their ability to minimize evaporation. I learned to use standard lab equipment such as micropipettes, genepix laser scanning imaging systems and prototype industrial equipment. I learned to analyze data with JMP statistical analysis software. I also learned to summarize data and present results at weekly team meetings.