After 3 years at Markforged (a 3D printing startup in Boston) I was made technical lead of the Metal X 3D printer. As a part of this role, I was tasked with leading the second generation refresh of the machine. This refresh included several functional and aesthetic changes as well as a recertification to a new safety standard in the EU (IEC 62368-3).
At a high level, the 3D printer works by printing a conventional filament with a high metal powder loading. This enables the printer to operate in an office environment without high temperature components or more dangerous powdered metal. After printing, the part goes through a 2 part de-binding process in an industrial de-greaser and high temperature sintering furnace.
Leading the project, I guided the team through the complete NPI process from design ideation, prototyping, testing & certification, production ramping, and launch in under a year while achieving an overall cost down on the BOM.
The second generation machine required the integration of a single fault tolerant safety system that electrically disconnected dangerous parts of the system once they became accessible through an open door. It also included an upgrade from a 4.3” internal display to 7” touch display on an arm - a design owned solely by me.
My responsibility as project leader also included:
Safety system architecture and layout.
Design of complex and highly cosmetic sheet metal modules with integrated electronics.
Creation and maintenance a detailed program schedule and phase gate process documents.
Delivery of detailed designs and drawings to sourcing team for prototype builds.
Coordination and completion of safety and EMC compliance testing.
Writing and presentation of detailed status updates to engineering and executive leaders
Release of final design packages to operations and sourcing teams for production ramp.
Oversight of pilot builds at factory in conjunction with operations and manufacturing teams.
This project was an incredible learning experience for me. I had exposure to every level and detail of new product creation that is invaluable to my practical knowledge and skill of bringing a product to market.
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