Flux Marine - Mechanical Engineer
Bristol, RI | Jul 2024-Present
- Developed in-house vacuum stator potting process for high-power electric motors, designing custom tooling and enabling internal prototype production.
- Achieved approximately 80-90% fill rates supporting 500+ hour endurance testing and stable thermal performance.
- Built and validated internal potting equipment, defined process parameters with resin suppliers, and developed scale-up plan for automated production.
- Led propeller development for 115HP electric outboard, creating automated performance analysis tools for system and propeller efficiency across test runs and enabling selection of a new propeller that improved efficiency by approximately 13%.
- Took ownership of drivetrain architecture across shafts, belt drive, bearings, and prop shaft systems to improve torque capacity, reliability, and manufacturability.
- Implemented drivetrain changes enabling approximately 18% increase in system power and reducing shaft-system cost by approximately 11%.
- Built first full landed-cost model of propulsion system and led a cross-functional effort identifying $11k per-unit savings, approximately 10.2%, without new tooling.
- Built and executed corrosion and coating validation program including saltwater cycling and galvanic testing to evaluate production-ready systems.