Grace Chen
Grace Chen ©
Portfolio Presentation
I love:
Creating, designing, building, using my hands, planning!
Potomac, MD
202-579-2323
gracezkchen@gmail.com
journeys.dartmouth.edu/gracezchen24
Education:
Dartmouth College (BA, BE)
Cornell University (MEng)
Hard Skills:
CAD (SolidWorks, Fusion 360), Rapid prototyping, MATLAB, C, GD&T
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My love for creating translated perfectly into mechanical engineering, specifically product design & development. I am extremely well-rounded & enjoy seeing ideas come to life.
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List of Featured Projects
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See my website for more projects!
Rev: Ithaca Startup Works
Hardware Product Development Assistant
Jan 2025 - May 2025
→ supported startups: EquiPad & Marrs Solutions
Equipad:
Marrs Solutions:
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GE Aerospace
Hybrid Electric Mechanical Intern
Jun 2024 - Aug 2024
→ Revamped & monitored the entire engine oil sampling & analysis process by communicating with 5 other teams, created a new standard order of procedure for draining and refilling a lube system with new oil
→ Interpreted 28 groups of SEM data for size of particle, chemical composition of particle, and the potential origin of particle within the motor generator/lube system, specifically looking for harmful particles that could damage engine rotating parts
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GE Aerospace
Hybrid Electric Mechanical Intern
Jun 2024 - Aug 2024
→ Modified electromagnetic interference (EMI) shield assembly instructions to properly reflect the new model with the use of NX software
→ Assisted in characterizing the reasons of failure of an x-ring in the stator of an engine by examining thermal properties and o-ring squeeze calculations
→ Completed and passed a 35hr course on GD&T per ASME Y14.5 standards
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Aerospace Corporation
Small Satellite Mechanical Design Intern
Jun 2023 - Aug 2023
→ Designed plates and hardware for vibration testing, ground support equipment, and other tests needed for flight programs (Aerocube 13 & DiskSat) using SolidWorks
→ Drafted 50+ drawings of flight components using GD&T per ASME Y14.5 (more than ½ of the components for Aerocube 13), worked with machine shop to fabricate parts, monitored process through Jira Agile, & released through PDM process
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Aerospace Corporation
Small Satellite Mechanical Design Intern
Jun 2023 - Aug 2023
→ Composed assembly instructions for RF ground stations that consisted of 10 different assembly documents by identifying missing information & conversing with other departments, which allows xLab to create their own ground stations
→ Assembled 3D-printed models of previous flight programs (tapped holes, inserted helicoils, used fasteners) in a lab environment
→ Conceptualized how to build a satellite in space and what the in-space satellite assembly factory would look like
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SAVIpress – Consumer Product Design
MEng Capstone Project
Aug 2024 - May 2025
→ about the product: an acupressure inspired massage footrest for students
→ leader, contributed to design, testing, etc.
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SAVIpress
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Objective: redesign the student experience so that they don’t just get by but thrive
Define the Problem: understand users before designing
→ empathy field work: created an emotional donut & lists needs, insights ,surprises
Define the Problem
→ how might we: design a system that creates more time for busy college students while also promoting relaxation?
→ flow of thoughts
→ personas
→ point of view diagrams
→ persona capability diagrams
Ideation: brainstorming – our top 3 ideas were:
SAVIpress
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Decision: after feedback, chose the acupressure rocking board
Testing Design Zero
Prototype: create Design Zero
→ cardboard & tape
→ conjoint analysis
→ user testing
SAVIpress
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Testing Design One
Iterate: create Design One
→ acrylic, foam, PLA, COTS acupressure pad
→ user testing
Iterate: create Design Two
→ MDF, foam, �PLA, rubber
Reevaluate:
→ better acupressure pad
→ add electrical components
SAVIpress
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Testing
Iterate: acupressure pad – explore silicon hardness and silicon molds
→ integrate 3D printed spikes into the silicon!
→ changed layout to reflect the shape of a foot for more accurate mirror Chinese reflexology zones
Iterate: electric modules
→ vibration, heating, fan module & buttons for control
Iterate: base refinement & other testing
→ 20 degree angle incline based on additional user feedback
→ 3D printed casing with foam layered inside
→ conjoint analysis
SAVIpress
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Final Prototype:
→ both works and looks like
Mars Rover: Insane Crane
Machine Engineering Project
Sep 2023 - Nov 2023
→ about: build a “Mars Rover” that can traverse different terrains and pick up “alien artifacts”
→ led gripper design
→ operated rover during competition
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Mars Rover
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Objective: design a robot that fits inside the starting cube, can pick up items and traverse different terrains, and can get back to the starting cube within 5 minutes
Gripper Sprint:
→ rapid prototyping: laser cut, 3D printed worm gear and gears, servo, hot glue
→ testing
Iterate: Gripper
→ testing results: good for �power cubes, but not so well �for the alien artifact �(triangular shaped) & bearings
*rest of presentation focuses on gripper since I was the lead designer for it
Mars Rover
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Iterate: Gripper
→ bucket & door design
→ testing
Iterate: Gripper
→ refinement
Iterate: Other Modules
Mars Rover
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Final Prototype:
→ I was responsible for operating our rover during the competition (I had to practice A TON)
RecyClean
Rapid Prototyping Project
Jan 2025 - May 2025
→ about: a recycling sorting robot!
→ leader of group, mechanical design/CAD lead
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RecyClean
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Proposed Idea: an automated recycling sorting robot that picks up, categorizes the recyclable (glass, metal, plastic), and puts it in a storage bin
Cardboard Prototype: created 2 versions of cardboard prototypes
→ rapid prototyping: cardboard, tape, paper, scissors
→ modules: ramp/feeding system, conveyor belt, gripper arm, storage bins, camera/automation
Initial Prototype
→ rapid prototyping: 3D printing, laser cutting, COTS materials
Tools Used:
→ Computer Aided Design (CAD): SolidWorks & Fusion 360
→ 3D printers, Laser cutting
→ Arduino programming - ESP32
→ Electronics (servos, stepper motors, keypad, camera module, LCD display, etc.)
→ COTS parts (bearings, PVC pipes, shoulder bolts, etc.)
RecyClean
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Testing & Iteration – Decision:
No More Automation: time constraints
→ user controls robotic arm joint movement by pressing keys on a keypad
→ allows for more interaction with the robotic arm (since we are presenting the project to children)
Testing & Iteration – Decision:
Camera Categories: ML model had trouble detecting plastic vs. glass
→ decided to detect for cardboard instead of glass, so three categorizes became metal, plastic, and cardboard
Testing & Iteration: Conveyor Belt
→ Added another DC motor to turn the other PVC pipe
→ Bolted the DC motors to the walls of the conveyor belt allowed the motors to just turn the PVC pipes and not turn themselves
→ Tried a new mesh like stretchy material for the belt itself and it worked well
→ Added friction to the PVC pipes themselves by applying some layers of hot glue
RecyClean
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Testing & Iteration: Robotic Arm
→ Used another power converter with a higher amp rating for first joint
→ Reprinted the stepper to PVC pipe connection at the bottom so that the inserted press fit into the PVC pipe is longer, providing more support
→ Bolted and secured the entire base to a large wooden plank
→ Reprinted the gears to be of larger diameter to decrease play
Testing & Iteration: Camera
→ Mimicked the lighting conditions that it was trained for during our demo (by flashing a flashlight onto it)
RecyClean
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Final Prototype:
Dartmouth Formula Racing Redesign
Undergrad Capstone Project
Sep 2023 - Mar 2024
→ about: redesign & manufacture the �pedal package and steering system
→ project manager, part of pedal redesign �team, supported steering team
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DFR
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Original Scope: included pedals, steering, cockpit seat, and nose cone
Rescoped: to exclude the nose cone and complete cockpit seat (just deliver the dimensions of the seat)
Objective: redesign & manufacture the pedal package and steering system in the current DFR car, and provide the team with seat padding specifications
the following slides will first talk about the pedals (which was my main team) and then about steering
Design for Inclusivity: Following user testing we realized that inclusivity became an important design factor for us, so we changed our goal from designing for 5th-95th percentile standard to 1st percentile female to 99th percentile male
Mike Chapman Meeting: (rulemaker of the competition)�→ determine way to share our designs with the wider collegiate formula racing community
→ change rules & encourage other collegiate formula racing teams nationwide to engage in the same design challenges
→ discussions about gender inclusivity in the automotive industry
DFR - PEDALS
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Goals:
→ increase adjustment range
→ reduce adjustment time
→ smaller footprint
→ maintain or reduce weight
→ withstand 2000 N
→ positive locking
Adjustment Range:
→ increase to 1st percentile female to 99th percentile male
Adjustment Range: Prototype
→ "Priscilla" and "Percy" & user testing
Adjustment Range: Prototype
DFR - PEDALS
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Adjustment Mechanism: Manufacture & ASSY
→ sheet metal bending tools, weld
Adjustment Mechanism:
→ want easy and fast adjustment mechanism for pedal package
Adjustment Mechanism: Iterate
→ user testing, advice from DFR technical inspector, FEA testing
Adjustment Mechanism: Research
→ got inspired by airplane seat adjustment mechanisms
DFR - PEDALS
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Pedal Package Footprint:
→ want smaller footprint, so have to look into master cylinder design
Pedal Package Footprint: Brainstorm
❌ Horizontal forward placed master cylinders → new pedal box, employing pull type pedals
❌ Relocate to side of pedal package → develop an adapter which transfers the linear braking motion from the pedals to the pushrods of the master cylinders, inefficient
✓ Vertical placed cylinders → placed at the rear of the pedals, but occupy less space
Pedal Package Footprint: Redesign
→ relocate brake balance bar
→ use Tilton 78-Series master cylinder model with spherical bearing mounts
→ match the mechanical advantage to 4.7
DFR - PEDALS
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Pedal Package Design:
→ pedal bodies, master cylinder mounts, ergonomics
Pedal Package Design: Redesign
→ add carbon fiber heel cups
→ determine mounting points for master cylinders
→ pedal and master cylinder mounts
→ mechanical stop
Pedal Package Design: Manufacture & ASSY
→ lathe and mill
Pedals: Testing
→ FEA testing
→ Instron testing to verify that pedal package can withstand 2000 N of force
DFR - PEDALS
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Final Pedal Package:
DFR - STEERING
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Goals:
→ reduce steering torque input
→ maintain or reduce play
→ maintain or reduce weight
→ comfortable wheel angle
Define the Problem:
Took apart steering components to determine sources of friction & play
Steering Shaft:
Implement oil impregnated copper-iron alloy bushings → strong, dependable bushing and decreases friction
Steering Rack:
Friction due to lack of maintenance → regreased
Steering Knuckles:
Interference between the upper suspension A-arm and the knuckle at full suspension droop → grounded down material
U-joint:
Transition from double U-joint to single U-joint
→ will decrease friction but will have a steeper drive shaft angle
→ new steering output curve
U-joint: Prototype
Used wooden frame prototype to determine that we need to shift the angle of steering wheel at least 8 degrees for single U-joint to be in the operating parameters of 0-35 degrees
DFR - STEERING
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U-joint: Prototype
3D Print adapter to mimic new angle for DFR approval → they approved the 8 degree change
U-joint: Redesign
Decided to have u-joint angle at 32 degrees
→ mitigated non-linearity
→ u-joint has removable set screws so the U-joint can be rotated 90 degrees (drivers can customize nonlinearity to fit their driving)
Steering Rack
Need to design a new steering bracket for single u-joint
Steering Rack: Redesign
Designed new steering bracket
Steering Rack: Manufacture & ASSY
→ sheet metal bending tools, weld
DFR - STEERING
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Steering: Testing
→ FEA testing
Steering: Final Steering System
Jack in the Box
Rapid Prototyping Project
Mar 2025
→ about: created a jack in the box toy
→ individual project
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JACK IN THE BOX
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Objective: design & create a jack in the box toy
Tools Used: understand users before designing
→ CAD (Fusion 360)
→ Rapid Prototyping: Laser cutting
→ Servos, electric components, breadboards
→ ESP32 (Arduino Uno Server, C/C++ code)
Thought Process
→ Decided to use a servo controlled rack and pinion to convert rotational to translational motion
→ Added engravings to the box for aesthetics
CAD
JACK IN THE BOX
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Assembly
JACK IN THE BOX
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Demo Video
Marble Maze
Embedded Systems Project
Mar 2024
→ about: joystick controlled marble maze game
→ partnered project
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MARBLE MAZE
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Objective: design a functional joystick controlled marble maze, in which a marble moves around the maze with the tilt of the game board.
Process:
→ paper design, input/output charts
→ pseudo code
→ code each module one at a time
→ build the game board
→ test, debug, test
→ play!
Group | Signal | Port | Direction | Function | Notes |
Motor Control | DirX�StepX DirY StepY | B0�B1�B2�B3 | Output | Dir. contr. X-axis Step comm. X-axis Dir. contr. Y-axis Step comm. Y-axis | Similar to stepper.c w/ TURN = 512 Forward & backward direction |
Maze Indicators | M0 M1 | B4 B5 | Input | Maze indicator 0 Maze indicator 1 | Photosensors controlled by states – external interrupt |
I2C | SDA�SCL | (C4) (C5) | Output | I2C data I2C clock | Both connected to sevenseg |
Position Input | joystickX�joystickY | ADC1�ADC0 | Analog In | X-axis control Y-axis control | ADC values from 0-1023, 450-575 buffer zone 0-450: left tilt; 575-1023: right tilt |
Push Button Inputs | userButton�joystickButton | D5 D2 | Input | Push button Push button on joystick | Toggles whether timer/stopwatch mode is on Toggles on/off of whole system Both: pin change interrupt |
LEDs | Red�Green | D3 D4 | Output | High true for red LED High true for green LED | Blinking during BEFORE state, on for STOP state On for PLAY state |
MARBLE MAZE
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Functions:
→ on/off toggle: initially “off,” to turn on/off press joystick button.
if idle in the “BEFORE” state for 120+ sec, automatically turn off
→ joystick: use the joystick to move the board in x and y
→ timer modes: stopwatch timer that can be toggled on by pressing the user button in the
BEFORE state
timer mode is off: displays “PLAY” and “STOP” in the stop state
if the timer mode is on: when PLAY state starts, game starts counting down. STOP triggered, user’s time is displayed & best recorded time is displayed; if user takes 120+ seconds, they lose and STOP state activated.
→ cheating: in BEFORE state, the game is activated by 3..2..1..GO being displayed; after GO is displayed, the user can trip the start sensor and start the game
if user starts before GO – they “cheated” and game goes to STOP.
MARBLE MAZE
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Game States:
→ BEFORE state: initially when the game is turned on or when the start sensor and stop sensor are both armed, the game is in the BEFORE state. As soon as this state is triggered, the red led
blinks on and off for five seconds, and then the green led blinks green for two seconds. Next, the
seven seg displays 3..2..1..GO. After this, as soon as the user moves the ball (and the start sensor
is moved), the game is moved to the PLAY state.
→ PLAY state: while the start sensor has been tripped and the stop sensor is armed, the game is in play mode. The seven segment display either displays “PLAY” or the time the user has been
playing depending on which timer mode they are in. (see timer modes). The green led is
activated in this mode.
→ STOP state: when the game is in PLAY mode and the stop sensor is tripped, or, the user cheats
(see cheating), the game is turned to STOP mode. The seven segment display reads STOP or the
user’s time and the fastest time depending on the timer mode (see timer mode). STOP state can
be changed to BEFORE state by arming both the start and stop sensors. The red led is activated
in this mode.
MARBLE MAZE
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Demo Video:
Contact
journeys.dartmouth.edu/gracezchen24
gracezkchen@gmail.com
(202) 579-2323
Website
Phone
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Thank You!
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