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Professional engineering
Product Validation & DFM
A validation and redesign program that identified an early wear failure, guided iteration, and prepared a flagship product for production.
- Period
- 2024–2025
- Role
- Staff Mechanical Engineer, Zonit
- Methods
- Root Cause · DFM · Injection Molding · Validation
>2×product lifespan
Engineering Challenge
A flagship locking product needed a quantitative picture of its wear behavior and a manufacturable path to improved life without sacrificing locking strength or standards compliance.
Approach
I established the test method, evaluated more than 100 samples, documented the failure mode, iterated the geometry, and brought the design through three injection-molding reviews with outside experts.
Results
The work more than doubled product lifespan, improved the failure mode toward UL requirements, increased locking force, and produced a design verified for mass-production readiness.
Key Outcomes
>2×product lifespan
- Revealed product failure in fewer than 30 cycles
- Executed testing across more than 100 samples
- Authored clear test plans, reports, and actionable results