Boeing

Additive Manufacturing & Prototyping Intern (Summer 2024)

During Summer 2024, I worked as a Design/Build Manufacturing Intern at Boeing's Additive Manufacturing and Prototyping Lab. The lab designs, fabricates, and post process wind tunnel models, various prototypes, and other parts for the entire company. In this role, I gained hands-on experience with the various manufacturing processes in the lab including Direct Metal Laser Sintering (DMLS), Stereolithography (SLA), Fused Deposition Modeling (FDM), machining, and even resin casting. During my internship I primarily worked with the DMLS team and got extensive experience with designing parts for DMLS, topology optimization, build file preparation, running printing simulations, setting up printers, operating the printers, and post-processing DMLS parts. 

While at my summer internship, I got the opportunity to work on a couple projects of my choice to help teach me about the various processes in the lab and help to further build my skills. As a result, the personal projects below are not covered by NDA. 


Example Personal Projects

Titanium Jewelers Saw

For my primary design project, I designed a custom titanium jewelers saw using topology optimization to make it lightweight but stiff. The saw frame was printed using DMLS, while various handle designs were made using SLA, FDM, and resin casting. For more details on the project please click the yellow button above.

Titanium Plumerias

I designed a small plumeria (tropical flower) pendant to be printed out of titanium using the lab's SLM 280 DMLS printer. The plumeria was additionally tetrashelled to reduce internal stresses during the printing process.

Equipment Engineering Intern (Summer 2023)

At Boeing, I worked as an Integrated Aerostructures and Advanced Metal Structures Equipment Engineering Intern in Auburn Washington. Equipment Engineers are responsible for providing solutions to help maintain, modify, and acquire new equipment/machines. During my internship, I got assigned multiple safety and maintenance related issues with various machines.

This role consisted of a lot of project management. I led cross-functional meetings between other engineers, operators, fabricators, maintenance staff, and safety focals to learn about issues with the machines. Additionally, I worked on researching potential solutions, contacting outside suppliers, and writing reports on my findings and recommendations to solving the issues. 

Along with my projects, I took advantage of Boeing's intern events. I attended dozens of different tours, classes, and interviewed multiple different engineers and managers. I saw firsthand the different manufacturing and assembly processes used throughout Boeing's various Washington sites. Additionally, I got to see how Boeing utilizes different forms of additive manufacturing and even learned about smart materials.

Example Projects

Note: These projects consisted of off-the-shelf products. The information below is simplified to not disclose any information covered by my NDA.

Sourcing a Replacement Hydraulic Hose

On one of the machines, a hydraulic hose ruptured. Boeing Equipment Services ran out of spare hydraulic hoses and learned that the old hose model is no longer sold in the United States. I researched and worked with outside companies to source a new hydraulic hose model that met all the necessary specifications.

Ergonomic Solution to Loading Dies

Operators were getting lower back injuries from loading dies on a press by hand at an awkward position. I worked with the operators and safety focals to research and propose over a dozen potential solutions to prevent ergonomic injuries. One such product that I found is a lift truck that helps to lift and position the die into place instead. 

Portable Hydraulic Heat Exchanger

Maintenance staff were having issues with the hydraulic fluid on a machine overheating during maintenance. They wanted me to source a portable heat exchanger with an external pump attached to it. I worked on researching multiple heat exchanger options and sizing it to ensure it dissipates enough heat.