Machining of Model Lightsaber Hilt

Designed CAD model using Shapr3D and manufactured a multi-component model lightsaber using brass, aluminum, and delrin, operating machine tools such as the lathe, CNC mill, horizontal bandsaw, and tapping/threading equipment

Developed and implemented a detailed manufacturing process plan, optimizing machining sequences and tolerances to ensure proper component fit and assembly

Programmed CNC lathes and milling operations, troubleshooting machining challenges such as tool chatter, surface finish, and dimensional accuracy

Collaborated in a four-person engineering team, managing division of labor, CAD design, and shop coordination to deliver a high-quality prototype under tight deadlines