Ali Elakkari

Mechanical Design Engineer supporting high‑value manufacturing and process development through hands‑on manufacturing equipment design, troubleshooting, validation, and sustainment. Served as a project champion and technical lead on complex mechanical upgrades focused on safety, reliability, ergonomics, and throughput across extrusion, web handling, pelletizing, and material processing systems. Key Contributions & Impact: - Led end‑to‑end mechanical design of custom process and manufacturing equipment, from concept and 3D CAD design (SolidWorks) through installation, FAT/CAT, IQ/OQ, and production handoff. - Championed equipment modernization and obsolescence mitigation (motors, gearboxes, drives, controls, fluid systems, and vacuum systems), protecting critical, high‑value production assets. - Designed and standardized material handling and powder conveying systems (drum dumpers, closed conveying, gain‑/loss‑in‑weight feeders), delivering major improvements in EHS, ergonomics, dust containment, and efficiency. - Delivered process monitoring and control enhancements (thickness, width, tension, pressure, static suppression), improving product quality and troubleshooting capability. - Provided hands‑on troubleshooting and root‑cause analysis across hydraulic, pneumatic, thermal, and motion control systems, restoring production and implementing permanent corrective actions. - Led machine safety and safety‑critical design improvements, including guarding, static mitigation, and ergonomic lifting solutions aligned with safety standards. - Served as mechanical project champion for downtime‑sensitive installs, coordinating with process engineering, manufacturing, skilled trades, OEMs, and vendors. - Developed mechanical documentation, 2D drawings, BOMs, and CAD standards to improve design clarity and sustainment. - Supported new product introductions, process transfers, mentored engineers and supported equipment ownership transitions.

• Designed a case specific implant for a pediatric cancer patient that is 3D printed using titanium alloy • Worked on a flat foot study that involved mechanical lab testing on cadaver specimens

• Designed and modeled femur fracture cases using Solidworks • Meshed different models using Abaqus and ran Finite Element Analysis on complete assemblies with fracture fixation implants • Analyzed stresses in the implants and strains within the bone to predict failure modes

• Graded reports and assignments for materials testing lab and material science class • Covered classes and assisted in machine dynamics class tutorials

Worked with the Intramural Sports, Fitness, and Recreation department at Penn State Harrisburg. • Maintained building schedules • Collaborated with team to open and close the facility building • Contacted appropriate personnel for troubleshooting issues • Communicated efficiently with other staff members • Completed routine building checks • Implemented facility policies and procedures

Suspension Team leader for the 2018 Formula SAE team. FSAE is a student design competition to design and machine a formula style race car to be used in the FSAE competition in Michigan. The team was able to place 29th out of 114 teams with our first ever running car. • Designed and optimized suspension geometry using Optimum G software • Designed wheel uprights and wheel assembly and applied Finite Element Analysis to analyze stresses • Oversaw projects such as; braking, steering, and hub design • Collaborated with other subsystems for vehicle dynamics calculations and hard points design • Oversaw team meetings and assigned weekly tasks and deadlines for team members • Secured full sponsorship package for the team • Educated other team members on suspension components and engineering principles.

Summa Cum Laude

Transferred to Penn State University.