Project Leadership

Served as project leader for a multidisciplinary team of five designers and engineers at DiMonte Group, successfully managing timelines, deliverables, and client expectations.

Led weekly review meetings with Life Fitness engineers and designers, providing progress updates and collaborating to resolve design challenges.

Critical Design Decisions

Directed and implemented key design decisions that shaped product aesthetics, assembly, construction, and user perception, including:

• Exterior Component Design – Developed detailed designs for injection molded plastic and die-cast aluminum enclosures
• Seam Placement – Strategically positioned seams between panels for optimal functionality and visual appeal
• Structural Considerations – Determined the placement and quantity of fasteners, structural ribs, and panel clips to ensure durability, rigidity and ease of assembly
• Ingress Protection – Strategically designed seams to block or channel away moisture and cleaning agents, safeguarding sensitive electronics
• Order of Assembly – Developed a logical assembly sequence, prioritizing serviceability, error-proofing (poka-yoke), and minimizing assembly steps

Advanced Surface Modeling

Utilized advanced SolidWorks surface modeling techniques to create smooth, curvature-continuous transitions between faces, elevating the product’s luxury visual appeal.

Design for Manufacturability

Provided actionable recommendations to enhance manufacturability, focusing on:

• Welded Frame Design: Improved structural efficiency and assembly processes
• Elliptical Linkages: Suggested modifications to optimize strength, reduce cost, and simplify production
• Sub-Assemblies: Identified opportunities to streamline design for cost effective and scalable manufacturing