QC Testing Station

I was tasked with designing and building a complete testing station for production, focused on thermal calibration and leak detection of our new pyrometer sensors. This included creating detailed documentation and training materials to ensure consistent testing procedures and smooth handoff to production technicians. 

Thermal Testing Station 

During the development of our new pyrometer sensors, I engineered multiple custom oven setups to support thermal testing across each sensor iteration. To enable reliable data transmission in a 300°C environment, I designed a specialized passthrough system. This involved modeling a modified version of our existing oven and integrating a custom fixture into the oven door capable of housing up to 12 sensors simultaneously.

After team validation, I sourced CNC-fabricated specialty adapters from a third-party vendor and personally fabricated a stainless steel block-off plate and mounting solution to secure all 12 adapters. When the sensor design was later revised, I was able to retrofit updated adapters into the existing setup—verifying fitment and tolerances using SolidWorks to minimize downtime and rework.

Purge Air System

Leak Detection Container

Leak testing is critical to ensure each sensor maintains proper shielding gas integrity. To support this, I repurposed an existing vacuum-only chamber to hold up to 1 atm of internal gas pressure. This required fabricating a welded steel cage to maintain seal integrity under pressure and designing 3D-printed drill guides to accurately install custom hermetic connectors sourced for the system.

I collaborated with our engineering team to integrate their leak detection hardware and software into the workflow, streamlining the process for production use. Currently, I am designing a new pressure-and-vacuum chamber in CAD to replace the original cage setup. This next-generation system will offer improved usability, faster sealing, and more consistent performance for routine sensor validation.