values and processes abstracted; identities removed.
Materials/computational design R&D and machine validation platform used to rapidly develop cosmetics designs, novel polymers, and calibrate AM equipment.
Role & Scope: Drove parametric design of ISO/ASTM 52902 test artifacts; developed automated metrology programs; developed machine calibration techniques; implemented site-wide First Article Inspection and Statistical Process Control.
#Proof
Capabilities: Instituted SPC on priority CTQs (design fidelity; tear/tensile) • FAI artifacts in production + R&D use • MSA screen completed
Business impact: enabled $2M+ in revenue (FY24-25); product line earned BeautyMatters “Innovator of the Year” award.
#Methods & Capability
- Automated metrology: developed parametric ASTM 52902 + micro-tensile/tear artifacts. Used for polymer development, computational design, and production initiatives.
- Rapid calibration: developed AM equipment calibration processes, reducing calibration time from 1 day → 1 hour, and significantly increasing the quantity and quality of production data.
- Statistical Process Control: tied automated metrology system to SPC dashboards, enabling predictive equipment maintenance and site-wide quality visibility
- Design Transfer: SOPs + Documentation for 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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No parameter tuning during production FAI; all corrections re-verified before production/material/design screening resumes
| CTQ | Measurement Process | Gate | Trigger + First Fix |
|---|---|---|---|
| Dimensional fidelity across build | ISO/ASTM 52902 artifact; scripted per-feature error map | Within validated window across bed; outliers rare and isolated | Clustered high error region → recalibrate (focus/exposure/fluid) machine → requalify FAI |
| Feature retention (smallest + largest features) | Automated count vs nominal on coupon | All target features at intended scales | Systemic loss of smallest/largest features → confirm focus/dose within offsets → requalify FAI |
| Fiber straightness | Automated positional deviation across fibers | Low fiber deviation vs straightness baseline | >20% fibers above straightness baseline → confirm post-process traveler accuracy, increase exposure one step within validated window → requalify FAI |
Other variables monitored: Intra-fiber dimensional fidelity, film thickness uniformity, feature circularity, tear/tensile strength (ASTM D1708/D624), residue (UV-Vis), environment (temperature, RH, light) - to distinguish machine vs material
