3DEO – Torrance, CA

At 3DEO, a metal additive manufacturing company, I worked as an R&D Mechanical Engineer focused on improving the printer’s hardware and programming.

I led multiple cradle-to-grave projects, including developing a rapid build plate cooling unit, an optical and thermal sensor bracket, and a mist containment cleaning device. However, my most challenging and rewarding task came when I was asked to solve a problem with the curing process that was causing high part rejection rates due to uniformity issues.

The original process involved laying a thin layer of metal powder, spraying a binder, curing it with a heater, and using end mills to shape the layer. My goal was to optimize the curing process, but the complexity lay in the hundreds of layers that needed curing without disturbing the powder, all within a limited timeframe.

Instead of focusing solely on improving the heater, I took a step back to identify the root cause of the problem. I realized the real issue was not about heating—it was about removing moisture effectively from the layers. By shifting my perspective, I opened up new possibilities for solving the problem.

After testing several methods, I discovered a way to uniformly remove moisture without using the heater, drastically cutting down the time and improving part quality. This unique approach to problem-solving allowed me to deliver a solution that not only addressed the immediate issue but also enhanced the overall manufacturing process.