​Raptor Propulsion - Spring 2018, Summer 2018, Summer 2019

• Acoustic modal analysis using ANSYS Acoustics package for the following Raptor flight engine components:

  • Oxygen preburner​

  • Oxygen preburner fuel manifold

  • Oxygen turbine housing

  • Main thrust chamber

  • Complete oxygen system model below pumps and above thrust chamber throat

• Assisted in identifying modes contributing to damage during engine tests

​Raptor Propulsion - Summer 2019

• Complete design, analysis, and build of oxygen system tank press heat exchanger used on the Raptor engine

• Took design from concept to fabrication in 12 weeks

• HEX model required estimated flow rates, pressure drops, and temperature gains using cross-flow heat exchanger theory

  • ANSYS thermal and structural analysis for verification​

• DMLM printing for oxygen-resistant parts

• Brazing required for guaranteed rigidity (ignition hazard in high pressure & temperature oxygen)

• Heavy usage of 3-axis mill & lathe using carbide-tipped cutting tools

• Learned process of braze preparation, braze alloy application, and furnace heating procedure 

Raptor Propulsion - Summer 2019​

• Part of a small, agile team exploring early manufacturing methods for Raptor Vacuum engine nozzle extension

• Required cheaper and more effective option from traditional C103 Niobium

• Developed cheap, efficient, and effective method of manufacturing extension nozzles 

• Reduced cost and technician time from C103 nozzle manufacturing by an order of magnitude

• Learned orbital tube welding process and practiced on many miles of joined SS 316 tube

Raptor Propulsion - Summer 2018​

• Responsible for complete design and manufacturing of sub-scale oxygen and fuel water-flow pumps for off-engine pump performance testing

• Required tight tolerancing using GD&T for shaft parts, seals, etc.

• Required pump scaling equations and flow path sizing using incompressible flow theory and pump performance theory

• Used 5-axis EDM and 5-axis mill to create and replicate complex on-engine fluid geometries 

​Raptor Propulsion - Spring 2018, Summer 2018, Summer 2019

• Responsible for tracking and structural analysis of all bolted joints on the Raptor flight engine

• Built tool tracking and feeding inputs of structural analysis for each bolted joint intoanalysis program and recorded outputs for real-time analysis results based on input variation

• Allowed for Responsible Analysts to easily look up joint confidence given proposed operating conditions

• Maintained this tool over multiple engine configurations

​Raptor Propulsion - Spring 2018

• Junior Responsible Engineer for test stand

• Designed, analyzed, and tested preburner thrust takeout structure

• Designed and fabricated igniter tube assembly, purge tube assembly, and other ancillary systems for testing

• Provided on-console, real-time structural analysis in ANSYS for stand modified parts in high stakes situations in order to meet testing window

​Raptor Propulsion - Spring 2018

• Worked with Marotta to up-rate check valves for 75% higher pressure and much higher temperature operation from Raptor development engine to flight engine

• Updated valve bolted joint

• Changed valve seat angle and modified cracking pressure

Raptor Test Equipment - Fall 2017​

• Designed and built the then-in-development Raptor test stand water flow/fire suppression system for engine testing and component bay testing

• Provided analysis for "lights out" complete valve authority loss cases

• Sized system for all required surface area coverage and water flow in event of pressure-only tank control

Raptor Test Equipment - Fall 2017​

• Provided analysis for critical insulation level based on denser liquid oxygen and required test stand service temperatures

• Designed and built 300 ft long service piping to various component level test articles

• Designed and safed LOx dump lines for these test articles as well

​Raptor Test Equipment - Fall 2017

• Built a large, multi-person work deck as my first project at SpaceX

• Designed to factors of safety of 3 on yield and 5 on ultimate

• Accommodated for very large flow pipes and already in place flow service

• Performed structural analysis on entire structure including non-linear buckling analysis on support beams