Role
Mechanical R&D COOP
Timeframe
May-December 2019
Skills
CAD (Solidworks)
Experimental Design
Data Analysis
CFD Simulation (Solidworks Flow)
Matlab/Simulink
At Embr Labs, I worked as a Mechanical R&D COOP for 8 months mainly focused on building, testing, and validating thermal simulation tools to analyze heat sinks and system architectures for next generation products.
During my 8 months at Embr Labs, I worked with both physical and computer simulation testing to analyze performance metrics for their current product as well as solve long standing R&D questions for future product releases. The work primarily hinged around designing experiments, collecting and analyzing data, and communicating results to a variety of stakeholders such as Product Development firms, business team leads, and other members of the engineering team.
I’m proud to say that my work had a very significant impact on the development Embr Labs’ next generations device (the Wave 2, pictured above) and future research and development efforts at the company. The tool I built helped me answer long-standing R&D questions about heat sink designs, natural convective flows over different surface textures, and materials and alloys with a variety of thermal properties. When it came time to design the device the simulator also allowed me to analyze heat sink concepts and system architectures proposed to the company by the design consulting firm and give them feedback about their work as it related to our product goals.
Though my tenure was only 8 months I’m fortunate to have had a valuable opportunity to work on highly impactful solutions in a fast paced startup environment. Since the team was small and I was made the company’s leading expert on the CFD model I was made to teach myself about Solidworks Flow and validate my models independently which taught me valuable skills in troubleshooting and self sufficient design. It also honed my communication and documentation skills in presenting data and analysis and exposed me to communicating with a diverse set of stakeholders when presenting my findings.
Building a Thermal Analysis Simulation
Objective
Design of the next generation product placed increased analytical load on the R&D team to deliver quantifiable results
A decision was made that the team needed a tool that could increase analytical speed and capability
Decided on building a 3D simulation tool that would allow us to input CAD models and get quantifiable results
Solution Path
Used online tools to learn basics of Computational Fluid Dynamics (CFD) and simulation capabilities.
Defined boundary conditions through reproducing bench-top experimental results on known models
Designed simulation experiments to develop next generation product (heat sink) technical, thermal management requirements
Processed numerical results from thermal simulations in Matlab/spreadsheets and synthesized system level impact to various teams including: business team, R&D / engineering, design firm (visualizing results through intuitive graphs)
Challenges
Pinpointing certain boundary conditions proved challenging because many ended up being counterintuitive or unclear