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Benjamin K.
Global rank:
17,378 / 139,572
Skill pts: 5
ansys fluent Electrical Design Embedded Systems Engineering Finite Element Analysis Heat Transfer
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About

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Experience

  • Senior Mechanical Design & Product Development Engineer Product Development Technologies (PDT) · Full-time Jan 2020 – Nov 2025 5 yrs 10 mos Lake Zurich, IL, United States Led advanced mechanical product development projects from concept development through manufacturing release for consumer, industrial, medical, and technology-driven products.

    Worked within multidisciplinary engineering teams combining mechanical design, electronics integration, simulation, prototyping, and manufacturing optimization.

    Key responsibilities:

    • Developed complex mechanical systems, assemblies, and product enclosures using SolidWorks and advanced CAD methodologies.

    • Created production-ready engineering drawings, GD&T documentation, BOMs, and manufacturing specifications.

    • Performed structural FEA, thermal analysis, and engineering optimization to improve product reliability and performance.

    • Applied DFM/DFA principles for injection molding, CNC machining, sheet metal fabrication, and rapid prototyping.

    • Collaborated with electrical and embedded engineers to integrate PCBs, sensors, actuators, and control systems into mechanical products.

    • Supported prototype development, validation testing, supplier communication, and production transition.

    • Delivered engineering solutions for consumer electronics, medical devices, industrial equipment, and advanced technology products.

    PDT is a Chicago-area product development consultancy specializing in product strategy, industrial design, mechanical engineering, electrical engineering, software development, prototyping, and manufacturing support.
  • Embedded Systems & Hardware Development Engineer NAK Engineering · Full-time Aug 2017 – Dec 2019 2 yrs 4 mos Chicago, IL, United States Designed and developed embedded electronic products combining hardware, firmware, PCB design, and connected device technologies.

    Worked on complete embedded product development including system architecture, circuit design, firmware development, prototype testing, and production preparation.

    Key responsibilities:

    • Developed embedded systems based on STM32, ARM Cortex-M, ESP32, and other microcontroller platforms.

    • Designed embedded firmware using Embedded C/C++, RTOS concepts, interrupts, DMA, peripheral drivers, and communication protocols.

    • Created electronic schematics and multi-layer PCB designs including analog circuits, power management, sensor interfaces, and communication modules.

    • Implemented communication systems using UART, SPI, I2C, CAN, USB, Ethernet, BLE, Wi-Fi, and IoT protocols.

    • Performed hardware debugging, board bring-up, firmware optimization, and system validation.

    • Integrated embedded electronics with mechanical assemblies for complete electromechanical products.

    • Supported IoT solutions including connected devices, monitoring systems, and smart products.

    NAK Engineering provides full-cycle product development services including hardware design, PCB development, embedded firmware, software integration, and connected device engineering.
  • Mechanical Design Engineer Sunlight-Tech, Inc. · Full-time Jun 2015 – Dec 2016 1 yrs 6 mos Mokena, IL, United States Provided mechanical engineering design and automation solutions for industrial equipment, manufacturing systems, and custom engineering projects.

    Responsibilities included:

    • Designed mechanical assemblies, machinery components, fixtures, and automation equipment.

    • Developed 3D CAD models, production drawings, and fabrication documentation.

    • Performed mechanical calculations, stress analysis, and design verification.

    • Supported CNC machining, fabrication, assembly, and prototype development.

    • Improved existing products through reverse engineering and engineering optimization.

    • Collaborated with manufacturing teams to improve reliability, cost efficiency, and production performance.

    • Supported engineering projects from initial concept through installation and deployment.

    Sunlight-Tech is an Illinois engineering design and automation company providing product design, manufacturing support, robotics, and engineering consulting services.

Education

  • Illinois State University Bachelor of Science (B.S.), Mechanical Engineering & Electrical Engineering, Engineering Program Graduate 2010 – 2015 Activities and Societies: Engineering design projects, multidisciplinary engineering studies, technical development activities, and practical engineering applications. Completed a multidisciplinary engineering education focused on mechanical engineering, electrical systems, and integrated product development.

    Academic experience included mechanical design, engineering mechanics, thermodynamics, fluid dynamics, heat transfer, manufacturing processes, electrical circuits, electronics, control systems, and engineering analysis.

    Developed a strong foundation in multidisciplinary product development, combining mechanical systems, electronics, and engineering simulation methodologies for real-world applications.

Other experience

  • Nordic nRF54 Wireless Development Platform Analysis Conducted a comprehensive engineering review of the RoyalBlue54L Feather, a professional open-source wireless development board based on Nordic Semiconductor's nRF54L15 SoC. The work included analyzing multi-sheet KiCad schematics, PCB architecture, power management, debug infrastructure, and the Zephyr RTOS firmware ecosystem.

    Reviewed the complete hardware design, including the nRF54L15 application processor, onboard nRF52833 CMSIS-DAP debugger, nPM1300 PMIC, USB-C power subsystem, external SPI flash, NFC interface, and Feather-compatible I/O architecture. Evaluated system-level design decisions such as dedicated I2C buses, dual UART implementation, power domain management, and manufacturing readiness.

    This experience strengthened my expertise in modern embedded hardware design, Nordic wireless platforms, low-power system architecture, KiCad-based PCB development, production-ready design review, and embedded firmware integration using the Zephyr RTOS.
  • Founder & Lead Engineer | UAV Free-Space Optical (FSO) Communication System Development Designed and developed a complete UAV-based Free-Space Optical (FSO) communication system integrating mechanical engineering, embedded systems, optical design, PCB development, and intelligent tracking algorithms.

    The project focused on establishing a high-speed optical communication link between moving UAV platforms using precision laser alignment, real-time tracking, and embedded control systems.

    Key responsibilities and achievements:

    • Designed the complete electromechanical system architecture for the FSO communication terminal.

    • Developed custom embedded hardware and multi-layer PCBs for communication, control, sensor interfaces, power management, and motor control.

    • Designed embedded firmware using STM32 microcontrollers with DMA, interrupts, FreeRTOS concepts, and real-time control algorithms.

    • Engineered optical transmission and receiver subsystems including laser drivers, photodetector interfaces, optical filtering, and signal conditioning circuits.

    • Designed precision mechanical structures including optical mounts, enclosure assemblies, stabilization mechanisms, and manufacturable components using SolidWorks.

    • Performed engineering simulations and design optimization using CFD, FEA, and thermal analysis to improve structural integrity, cooling performance, and system reliability.

    • Developed real-time tracking and pointing systems integrating IMU sensors, fine-pointing actuators, optical feedback sensors, and closed-loop control algorithms.

    • Implemented communication interfaces including UART, SPI, I²C, CAN, Ethernet, and wireless telemetry for system integration.

    • Applied Design for Manufacturing (DFM), Design for Assembly (DFA), GD&T, and international engineering standards throughout the product development process.

    • Managed the complete engineering lifecycle from concept development, system architecture, simulation, PCB design, firmware development, mechanical design, prototyping, testing, validation, and preparation for production.

    This project demonstrates multidisciplinary expertise in aerospace systems, embedded electronics, optical communication, precision mechanical engineering, PCB design, control systems, and complete product development for advanced UAV applications.
Stats

Age: 34

Joined: July 6, 2026

Last seen: July 21, 2026

Area of Expertise
Electrical Engineering Interior Design Home Design Electronic Devices Drone Design PCB Design Services Internet of Things (IoT) FEA Finite Element Analysis 3D Solid Modeling 3D Models of Machine Parts Structural Steel Detailing Structural Design Services MEP Drafting Services Architectural 3D Modeling 3D Floor Plan Design 2D to 3D Modeling 2D Drawings and Floor Plans Radio Frequency Engineering and Design Services Electrical Circuit Design Services Civil Engineering Staffing Agency

Languages

English Native or bilingual proficiency

Location

Waukegan, IL, United States

Waukegan, IL, United States