Keurig Dr. Pepper

Systems Research Engineering Co-op

Burlington MA, January 2023 - July 2023

Keurig Dr. Pepper is a leading maker of single-serve coffee products and coffee brewers. During my time here, I worked on the ‘Brew Engine Design’ team that develops the internal components of the brewers and researches new technology to be implemented into them. I utilized computational modeling, CAD, and extensive hands-on experimentation in the lab to conduct investigations into components such as pumps, heating elements, fluid sensors, and the software that controls them as a system. I also assisted in the design of laboratory fixtures and housings, often utilizing 3D printing and machining to build custom parts. Projects I did here were:

Conducted a research initiative modeling how the dynamics of a 5-input system respond to change depending on how the system architecture is structured. This was done by running a LABView-based experimental analysis, developing a system model with Excel, and completing a JMP statistical analysis to better understand the data.
Built a mathematical model that predicts the cracking pressure of a release valve with a tolerance of 1 psi over a range of 35 psi, then designed and built a physical version of the valve for testing using Solidworks and SLA 3D printing. To build the model, I utilized Solidworks Fluid Simulation software and Python.
Designed a tabletop fixture that supports a brewer and contains all hardware necessary to connect it to a computer with one cable, eliminating several minutes from every future test.
Created tri-weekly A3 reports as part of an Agile workflow where I presented my work to engineering leaders and collaborated with other engineers.

Baker Hughes

Mechanical Engineering R&D Co-op

Skaneateles NY, January 2022 - July 2022

Baker Hughes is a multinational industrial service company that provides products and services to the oil and gas industry, specializing in oilfield services, equipment, and digital solutions. I worked in the Waygate Technology Remote Visual Inspection (RVI) division, which designs and assembles high-end commercial video borescopes for applications such as jet turbine inspections, wind turbine gearbox inspections or other custom use cases. Here I worked on designing new components in CAD, performed optics research in the lab, and updated testing protocol documents. Projects I worked on here were:

Designed an articulating assembly that moves a camera in a range of 180 degrees in three dimensions, building mock models of it during design iteration using 3D printed parts for concept validation.
Ran test protocols on new materials and components if their suppliers changed to determine changes in their characteristics and if they were suitable for production.
Designed a bracket with an integrated load sensor that measures the force from a servo and then worked with the electrical engineering team to calibrate it and implement it into a production probe handset.
Researched and tested a new abrasion and heat-resistant material (NOMEX) that protects a camera probe so that it can be used in high-heat, high-stress environments tripling the product lifespan.

Mack Molding

Sales Engineering Intern

Arlington VT, May 2021 - August 2021

Mack Molding is a manufacturing company that specializes in providing custom plastic injection molding and contract manufacturing services for a diverse range of industries, including medical, industrial, and consumer markets. As a part of the sales engineering department, my team and I worked to ensure our client’s engineering requirements and cost targets were being met on the production floor. I traveled to different company sites and oversaw launches of new tooling and assembly processes, meeting with clients and coordinating with operators. Here I:

Rebuilt an Excel-based finance model that tracks quote prices across a $3M+ account for a company in the life science and scientific instrumentation space.
Coordinated a production run of injection molded parts and unit assembly for a small exercise and wellness-oriented start-up.
Assisted with the launch of 4 new plastic injection molding tools into the production environment utilizing LEAN principles to ensure press downtime was kept as low as possible.

Kate Gleason College of Engineering

Engineering Design Tools Teaching Assistant

Rochester NY, August 2021 - December 2021

Rochester Institute of Technology's Kate Gleason College of Engineering (KCGOE) is an educational institution dedicated to fostering innovation and excellence in engineering education. During my time studying here, I took an opportunity to work as a Teaching Assistant for a freshman-level mechanical engineering class called “Engineering Design Tools.” This class focuses on teaching the fundamentals of engineering in a simplified engineering process - problem definition, brainstorming, conceptual design, prototyping, and production. The final deliverable is a pole-climbing robot made of basic materials like duct tape and popsicle sticks. In this role, I:

Assisted 65+ students with assignments, and helped them find materials and use tools in the lab and machine shop.
Designed a motor test fixture using Onshape that reinforces the concept of potential energy and power by using the student’s robot concepts to lift a weight over a known distance.
Graded homework assignments and provided feedback to the students while working with the class professors to assess and adjust the learning material.

Skills Utilized Onshape | Welding | FDM Printing | Student Instruction

Ben McAlonie

My Experience