values and processes abstracted; identities removed.
Additively manufactured mascara brush microstructures and novel materials enabling makeup application results impossible with other manufacturing techniques.
Role & Scope: Design owner for four cosmetics brushes; owned polymer-side parametric design + support-structure strategy; designed, built, & programmed an in-house brush bend fatigue rig; delivered weekly durability/throughput reports to customers & internal stakeholders.
#Proof
Capabilities: engineered and qualified 3+ novel resin formulations • delivered 4 novel mascara microstructures • designed, built, & programmed automated bend-fatigue rig
#Methods & Capability
- Developed bend-fatigue qualification platform, supporting the development of 3+ novel resin formulations.
- Authored and standardized test methods for bend fatigue and design fidelity analysis (hybrid metrology system); methods captured in SOP and trained across operators.
- Design Transfer: SOPs + Documentation for Print, Post-process, Quality inspection, Safety, and QMS handoff.
- Integrated Quality Controls: (GR&R pre-check, FAI on recipe change, go/no-go gates) ensured repeatability and traceability within QMS.
#Process
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Parameter Window
| Parameter Window | Primary Response | Control Window | Failure Signal | First Corrective Action |
|---|---|---|---|---|
| Brush Lattice Geometry | Bend Fatigue | Narrow → Moderate, formulation dependent | Bend fatigue or yield | Revert control cell type + requalify |
| Support Structure Geometry | Design Fidelity | Narrow → Moderate, formulation dependent | Distortion, support removal difficulty, yield | Restore baseline taper/profile + requalify |
| Print Energy Density | Tear Strength | Narrow → Moderate, formulation dependent | Increased bend fatigue and reduced tear strength | Reduce exposure one step within validated window + requalify |
Additional Variables:
Slice + layer exposure filtering, Resin removal, Dry-down, Post-cure Energy → controlled
