Mechanical Engineering Co-op | Boxborough, MA
January – June 2024
Quick Facts:
- Industry: Product Design & Consulting
- Company Size: Around 60 Empolyees
- Focus: Delivery Vehicle solutions
- Location: Boxborough, MA
Product Insight is a leading product design and consulting firm specializing in innovative solutions for the delivery and logistics industry. The company partners with major firms to develop custom fixtures, safety systems, and efficiency-enhancing modifications for next-generation delivery vehicles.
During my 6 month coop, I was able to work with their mechanical engineering team, going through the entire design cycle multiple times for different products.
My Role & Impact
As a mechanical engineering Co-Op, I was responsible for the complete product development cycle of custom vehicle fixtures and mechanisms. My work directly contributed to installations across 200+ delivery vehicles.
Core Responsibilities
- 3D modeling complex assemblies in Solidworks
- Prototype fabrication and testing
- Manufacturing documentation creation
- Client presentation preparation
- Cost analysis and material selection
- Quality control and testing procedures
Key Achievements
- Designed 15+ custom fixtures deployed fleet-wide
- Designed an E-chain system for a fast moving robotic arm
- Reduced installation by 40% through jig optimization
- Created assemblies with 100+ components
- Managed 3 concurrent prototype projects
- Presented designs to client stakeholders
- Zero safety incidents during testing
Technical Skills developed
Software
- Solidworks
- AutoCAD
- Figma
- MathCAD
- MS Excel
Manufacturing
- Waterjet
- Laser Cutting
- 3D Printing
Analysis
- GD&T
- FEA Analysis
- Cost Analysis
Professional
- Project Management
- Documentation
- Presentation
Featured Projects
WaterJet-Cut Precision Drill Jigs
Designed and manufactured custom aluminum fixtures for repeatable installation accuracy. These jigs ensured +-0.005″ positioning tolerance across installations
- Material: 6061-T6 Aluminum
- Process: Waterjet cutting with CNC finishing
- Result: 40% Reduction in installation time with great precision.
Sliding Door Safety System
Developed full-scale prototype for vehicle sliding door with integrated safety features. Led prototyping locking mechanisms and sliding fixtures.
- Conducted load calculations for bearing selection
- Integrated fail-safe locking mechanisms
- Tested through 1,000+ cycle durability
Acrylic Laser Leveling Fixtures
Created precision fixtures for mounting laser levelers in vehicles. Used clear acrylic for visibility and integrated alignment features for accurate installation.
Electronics enclosure prototype
Designed and prototyped custom electronics enclosures for delivery vehicle systems. The project required balancing thermal management, component accessibility and protection from environmental factors. Utilized aluminum extrusion frames with modular mounting systems to accommodate various electronic configurations.
(The image is not the full product)
Minsang Lee 