Payload interface, dispenser, and separation mechanism design

Starlink demonstration satellites ("Tin tin") at SpaceX

At the dawn of the Starlink program, SpaceX needed a payload dispenser to hold the satellites to the rocket and let them go just at the right time. The dispenser also had to accommodate PAZ, the primary mission customer. I was the responsible engineer.

I designed the pyrotechnic pin-pullers from scratch, as well as the separation pushers and the dispenser structure itself, and collaborated tightly with the team in Seattle to define the interface. All designed in NX, and analyzed with many hand calculations in conjunction with Femap/Nastran and ANSYS. Pin-puller operating dynamics were simulated in MATLAB. All hardware was shepherded through qualification and acceptance testing per SMC-S-016 prior to flight.

Tooling design, qualification test design, and program management

Iridium NEXT constellation at SpaceX

The Iridium NEXT constellation launch contract was one of SpaceX's first big commercial contracts. I designed tooling to ensure that the four interfaces, 10 feet apart, were built within .02" flatness on our composite dispenser. To validate our dispenser design, I designed an epic structural test to simulate launch stresses on the payload dispenser. Throughout the production process of the composite dispensers and the separation mechanisms, I kept internal and external production and test teams on schedule, rapidly addressed any issues with robust solutions, and worked with our mission management to ensure all hardware was ready for launch on time.

An ultra-high pressure pump for a research laboratory

The lab required equipment that could withstand extremely high pressure indefinitely, with the ability to handle a range of gases. I designed a custom dynamic seal that achieved leak-tight performance even with notoriously leaky gases like helium and hydrogen. I designed both hydraulic and pneumatic actuators, implemented in two different intensifier designs. To ensure structural integrity under ultra-high pressure, I performed hand calculations and used ANSYS Mechanical to simulate material behavior beyond its yield strength, particularly in non-cylindrical structures. Techniques like autofrettage and jacketed cylinders were studied and used extensively. Material selection was carefully tailored to meet environmental specifications. Additionally, I developed state machines to define the logic and operation of the intensifier systems and contributed to the software side by writing ladder logic for the PLC.

AZAK – A Novel Vehicle for Logistics in Remote Environments

AZAK’s new wheel technology enables innovative vehicle designs, and I contributed to the development of the S48 forklift project from concept to fabrication-ready CAD package. The project had stringent volumetric requirements that demanded creative solutions to meet customer performance expectations. I developed design loads and secondary requirements based on the customer’s core contract specifications. I designed custom assemblies using a combination of sheet metal and machined components, ensuring they were appropriately sized, detailed for manufacturing, and capable of being rapidly deployed and stowed in the field. Additionally, I was responsible for selecting and integrating COTS components—such as actuators and bearings—that met both displacement and structural needs while ensuring ease of use in demanding environments. Throughout the project, I documented key milestones and participated in concept reviews to ensure alignment with AZAK’s and the customer’s objectives. Ultimately, the project was completed to a point where AZAK could confidently proceed with the manufacturing and testing of an entirely new type of forklift, enabled by their S-48 wheel architecture. * Note: The vehicle shown on AZAK's website is not the designed vehicle, but it does illustrate the general idea