While working with Heller Ovens to develop a thermocouple lead compatible with their custom passthrough posts, I encountered an urgent challenge: standard off-the-shelf leads were either too large to fit into the M2 post or used materials that couldn’t withstand temperatures above 200°C. During the evaluation process, I identified dimensional discrepancies in the internal engineering drawings that conflicted with real-world fitment. After validating these measurements, I discovered that standard Type K thermocouple leads offered both the correct clearance and the necessary thermal tolerance. This solution not only resolved the fitment and material issues but also significantly reduced cost and lead time for deployment. 

After sourcing suitable thermocouple leads, I needed a reliable method to join the alumel and chromel wires for use in environments exceeding 200°C. I tested both a custom crimping approach and a spot welding process to evaluate strength and consistency. Through experimentation, I developed optimized spot welding settings for 30-gauge wire, achieving a tensile strength of 5 ft-lbs—significantly stronger than the 3 ft-lbs produced by crimping. This method not only enhanced mechanical reliability under thermal stress but also standardized a more consistent attachment process for production use. 

Following the development of the optimized spot welding process, I designed an outer sheathing assembly to reduce electrical noise from the reflow machine and enhance insulation performance. I generated complete assembly documentation, a detailed bill of materials (BOM), and a cost breakdown to support budgeting and sourcing decisions. This solution improved signal integrity while maintaining manufacturability and cost-efficiency. 

After finalizing the thermocouple design and bonding process, I worked with operations to implement the solution into full-scale production. The design met all thermal, dimensional, and cost requirements, eliminating the need for expensive custom components. Since implementation, it has been installed in dozens of machines and has operated with zero reported failures. The project was later featured in our company-wide newsletter as a spotlight innovation—recognized for its engineering rigor, cost-effectiveness, and contribution to improved production workflows.