Embedded with an engineering team at a PCB manufacturer supporting aerospace and high-reliability products, gaining hands-on experience across SMT production, AOI/flying probe testing, quality control, and process improvement. Worked directly alongside engineers on the production floor applying IPC/ISO standards and running root cause analysis on real failures.
Designed a custom ESD-safe protective cover to prevent conformal coating contamination on LCD components. Modeled the enclosure in SolidWorks using component dimensions sourced from DigiKey, applied GD&T tolerancing to ensure proper fit across multiple product families, then prototyped using Cura and an Ultimaker S5. Solution was scaled across the D800s, ES3, and MC2 product lines.
Built a structured Excel-based tracking system to standardize RMA failure data collection during investigations. The system improved visibility into failure trends and root causes, replacing an ad-hoc process that was slow and inconsistent.
Developed Python scripts to automate flying probe validation workflows that previously required constant engineering oversight. The automation enabled operators to run tests independently, freeing up engineering time for higher-priority work.
Expanded flying probe test coverage across the D800s, ES3, and MC2 product lines by implementing new testing procedures. Improved detection of electrical faults during production before boards reached downstream operations.
Designed a Python-based system to validate BOM consistency by comparing MRP BOMs against SMT machine pick-and-place data, flagging mismatches before production began. Reached concept and design stage during the internship.
Conducted a cost analysis across multiple packaging methods, evaluating material and labor costs for each approach. Identified process inefficiencies and documented optimization opportunities with supporting data.
Developed a deep understanding of the full PCB manufacturing lifecycle. From BOM validation through final testing and failure analysis. Saw firsthand how design decisions made early directly impact manufacturability, cost, and defect rates downstream. The gap between an ideal FMEA and how quality teams actually run root cause investigations on a production floor is significant, and I came away with a much clearer picture of how to bridge design and manufacturing.