Zachariah Sprys

• Lead the mechanical design and manufacturing of the Internal Research and Development (IRAD) project developing systems to meet the electrical, mechanical, and environmental requirements using machine tools and 3D printing • Prototyped electronic potting template for rapid development and system level analysis highlighting DFA and repeatability • Developed glass machining capability, overhauled a traditional CNC machine for intricate glass milling, proved with over 80 hours of successful machining time • Diagnosed pressure transducer sonar impeding noise source to a particular component and evaluated sound dampening solutions • Analyzed electro-mechanical assemblies meeting the structural and thermal requirements of submarine environments using Ansys • Designed and manufactured circuits matching the desired variability tolerance using conductive inks via an ink-equipped 3D printer • Corrected circuit schematics through team communicated modifications for future builds, increasing cable and circuit reliability ensuring DOD compliance • Lead budget tracking for IRAD project expenses, ensuring all expenses were accurate and communicated through upper leadership • Reduced part count by 50% using Ansys for circuit thermal load analysis while maintaining safe operating temperatures • Conducted root cause failure analysis on Naval sub-sea mission-critical components using Solidworks FEA and PTC Mathcad stress calculations to determine material deformation cause, ensuring part reliability • Utilized PTC Mathcad and Microsoft Excel to determine assembly tolerance stack-up following ASME Y14.5 with a working knowledge of GD&T • Authored multiple project deliverable technical documents outlining the results of DVT analysis on Naval hardware • Increased prototype turnaround time by 85% by providing employee training on FDM 3D printers, resulting in higher quality parts

• Owned manipulator to vehicle integration design through concept generation, prototyping and the final product • Generated full product drawing package adhering to GD&T standards and reviewed DFM with manufacturing staff • Documented assembly steps through first article assembly and work instruction review • Rapidly iterated design testing through prototype development using 3D printers and machine tools • Adapted quickly to plan changes to complete the required testing for customer requirements • Identified and fixed critical points of improvement while testing first article manipulators through environmental testing • Completed finite element analysis on multiple parts to determine material reduction areas and verification of design • Designed thermal interface and performed thermal calculations determining adequate cooling methods • Designed and developed above and below-water test stands for manipulator testing and validation working with multiple disciplines • Increased production quality by working with technicians facilitating drawing and instruction interpretation • Cut project costs through management of 3D printing capabilities by operating and maintaining three machines, initializing a streamlined request service and increasing capabilities through new machine purchase • Executed design verification testing on a subsea gripper through pressure and environmental testing with DoD personnel • Customized and tested material options on replacement gripper fingers to reduce the risk of high-value components by developing 3D-printed molds and using silicone molding techniques • Designed compact electromechanical housings with a focus on material minimization and thermal management

• Satisfied customers through accurate order fulfillment with a 90% on-time completion time • Ensured salesfloor products were accurate through price correction, product placement, and product stocking

• Enhanced student projects using a manual mill, manual lathe, CNC mill, CNC lathe, plasma table, wire EDM, drill press, soldering iron, laser engraver, TIG welding and other hand tools • Ensured part accuracy through interpretation of shop drawings and models to create tool paths and perform machining operations using Creo Parametric • Increased shop efficiency by assisting students in manufacturing senior design projects, personal projects and classwork • Accurately performed and documented material and fluid tests using LabView.

• Tripled the load capacity of the pneumatic actuator through mechanical modifications to the system • Completed project milestones by proving our conveyor concept through real-world application using industry equipment • Accelerated computer vision work through prototyping accurate manipulator camera mount fixture

• Ensured business operated smoothly through daily operation management and maintaining store hours • Supervised and trained employees on different tasks, customer interaction, and event planning • Ensured customer satisfaction through accurate accounting records, product sales, and full cycle entertainment experience

Leader of a unique engineering competition where students are tasked to create a solution to a given problem. Examples have been a human-powered autonomous vehicle and a giant underhand cornhole launcher.