https://www.zachary-howell.com/personal-projects daily 0.75 2024-01-05 https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602999373814-NID3WHE449FYI0C7V2K8/01-2.jpg Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602999388329-EO7B0CJW6YG8K84J56K3/3.jpg Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602999388700-2YRNPIJFT0BEEQ0WEYUJ/7.jpg Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602999405388-IOCCEUJ1V5VXROC00UB0/10.jpg Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602999403269-PYIEN8343IRCQPPAUJ6R/R1+SHOT+%283%29.jpg Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602999417216-Q7SFYASIG1KDFDAXDJAB/R1+SHOT+%286%29.jpg Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602999411936-DJXZ1DWPECVSEG5HVJ7O/R2+SHOT+%286%29.jpg Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602993322024-AI5OGQ1NS7HD5JYS7LCQ/20200513_174950.jpg Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602993320974-03ERRB1I96QYXGDYA2O1/20200513_175001.jpg Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602993329698-CRCJQJMJD0S1E2JF2R1M/20200513_175029.jpg Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603095703600-6O1AUY7XTBJJYACEG02I/STL+file.JPG Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602993305649-3FLBFO5OA2O6APIT7AZR/20200510_160929.jpg Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603191516332-W18ILW5ML95OWRJ8BCN6/Untitled-1.png Personal Projects - Frame Design Refinement The failure analysis revealed opportunities for improvement to the design, including the expansion of cross-sectional areas near motor mounts and the removal of unnecessary material to lessen the drone’s weight. These improvements, as well as several quality-of-life changes, were incorporated into the second design iteration of the drone frame. This version of the frame has flown flawlessly, even after several hard crashes. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603188486448-I60PKSE9K8SPVBR4T2M6/FPV-Drone-Parts.png Personal Projects - Parts Ordering In order to have a well-functioning drone, I had to obtain parts that were both adequate for the frame and the style of flying. All the parts had to be compatible with one another as well. This process proved to be more difficult than initially anticipated, as there is a fairly steep learning curve. Once proper component research had been completed, a comprehensive and optimized bill of materials was produced and orders were sent out. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603100569095-ZAZU6EUQB8MRT8ZX3M3M/ezgif.com-gif-maker.gif Personal Projects - Simulation Analysis Once the frame was designed, it was necessary to validate that design with engineering calculations and simulations. In addition to basic solid mechanics checks, various finite element analyses were performed within SolidWorks Simulation- including drop tests. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603227859723-2B66C78RR6JPR8YDFB3W/Drawing.2.JPG Personal Projects - Frame Design The first stage of this project involved designing the 3D-printed frame. Unlike the popular carbon fiber frames that saturate the frame market, this frame could not be a simple, flat extrusion of a profile sketch. Instead, I had to use my knowledge and intuition of solid mechanics and aerospace structures to design a frame that could be made of PLA plastic and still withstand the stresses of inherent to drone flight and the occasional crash. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603187914035-1Y8HEOG0EG2DQVX1T6LW/20201002_080931.jpg Personal Projects - Frame Manufacturing With the parts on their way, the next step was to start production on the frame itself. I was able to use my additive manufacturing experience to generate quality frame components in a relatively short amount of time. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603096900720-RWVNH3J57HKGYAZN3KCH/20200927_000542.jpg Personal Projects - Electronics Assembly/Config Once the frame was printed, it was necessary to assemble the electronics and configure their firmware. The components of the electrical subsystem included the flight controller, electronic speed controller board, battery, FPV camera, radio receiver, and video transmitter. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603099242928-KNB3X2S5Z3JZ6KW7S3M1/Failure+Combo.png Personal Projects - Flight Testing & Failure Analysis With the frame and electronics assembled, it was time for the fun part: testing! The drone’s first flights went exceptionally well; the craft handled well and all components behaved as expected. At the end of the first flight session, however, the drone suffered a hard crash and one of the arms failed at the motor mount. This provided a great opportunity to perform failure analysis and apply the lessons learned to future revisions of the design. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1602998427851-9O17IIAP8TU6WNI9TUXC/Banner_10.png Personal Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603000592115-ASTP3SOL3HHKOIVZTCQD/Banner.png Personal Projects https://www.zachary-howell.com/experience daily 0.75 2025-06-23 https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603165068209-HUSKZ7WTAUXH5HHMNEZL/CovidFree.png Work Experience - Working within COVID-19 Limits I have demonstrated an ability to produce substantial results in a physically limited environment due to COVID-19 restrictions. This has only been made possible through careful planning, effective use of web-conferencing and organizational tools, and strict adherence to safety regulations. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1607464619298-1NA5BF1F5Z09I22LSH1L/20201113_163754.jpg Work Experience https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603165460763-QKCXD1JPRLU7JDE26P9J/tools-1209300_1920.jpg Work Experience - Management of Part Ordering To help the team meet its material needs, I have overseen the submission of several parts orders, which have totaled over $8500. This process involved the generation and optimization of detailed bills of materials, which allowed the team to focus on the task at hand without waiting on the shipping times afforded by a waterfall approach to parts ordering. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603524946058-FWRSR4R416B1D07TP4FV/Schlieren%2BSetup.jpg Work Experience - Optics Setup I have assembled and calibrated the optics used within the lab, including a Schlieren photography setup. The proper setup of these optics allows consistent visual data to be collected during experimentation. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603524883848-DA6SC3QI39AJDBNTBYT8/schlierenSetup.png Work Experience https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603165570837-3CH4WQK6L8UCQKFBFRRN/pexels-startup-stock-photos-7376.jpg Work Experience - Organizational Setup In order to help the team maintain a high level of efficiency, I have implemented several organizational and web-conferencing tools - including Todoist, Zoom, and Discord. These tools help the team stay on track and communicate effectively with one another. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/e0fff9fa-6c33-468a-92a1-319dd73ecf6f/blue-laser.png Work Experience - Mechanical Engineer II I worked at Essentium as an R&D-focused Mechanical Engineer II. My primary responsibility in that role was developing a novel blue laser DED microwire metal 3D printer - a major deliverable within a multi-million dollar DOD/AFRL defense contract. By engineering over 200 components across three generations of the machine, serving as DRI for the printhead subsystem, and performing a myriad of other engineering tasks, I helped my team push the project through several hard-fought contract milestones. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/dbc8af55-079a-4972-92c4-ad91f5f01a98/trends-3d-printing-at-scale.jpg Work Experience - Additional Responsibilities During my tenure as an engineer at Essentium, I actively sought and embraced opportunities to contribute beyond the responsibilities explicitly listed in my job description. I believed that adopting a more holistic approach to employment would better help Essentium, its customers, and my fellow employees find success. This including serving as a member of the Culture Committee and leading lab organization and cleanup efforts. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/e35496de-d213-4a7f-97eb-6d3de3d2ef7f/Generic+Engineering+Photo.jpg Work Experience - Applications Engineer I My time at Essentium began when I joined the company in early 2021 as an Applications Engineer, excited by the prospect of working on the cutting-edge additive technology that I had developed a passion for at university. As an Applications Engineer, I developed novel applications for Essentium’s industrial HSE polymer 3D printers and filament. I also provided field service engineering support by troubleshooting complex machine issues, conducting on-site installations, leading training sessions, and collaborating cross-functionally to enhance product reliability. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/a0e52a59-1275-4775-91ae-0a9234843622/Essentium+Bay+1.jpg Work Experience - Essentium, Inc. Emerging from its roots as a developer of high-performance 3D printing filaments, Essentium, Inc. was established in 2018 to be a provider of industrial additive manufacturing solutions. This incorporation represented an expansion in the company's scope to encompass a complete ecosystem: high-speed, large-format 3D printers like the HSE platform, a diverse material library (including nylons, PEEK, and ULTEM), design and optimization software, and dedicated consultation services. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/4262b401-117f-412d-a1de-e9cf204290eb/1000w_q95.jpg Work Experience - Northrop Grumman - GSSC [INSERT DESCRIPTION OF TEAM] - Contract = GSSC - Sustainment of LGM-30 Minuteman III ICBM - Ground Mechanical Team - Lead of Launch-Critical Subsystems https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/e35496de-d213-4a7f-97eb-6d3de3d2ef7f/Generic+Engineering+Photo.jpg Work Experience - ??? [???] - Skills Development (GD&T, NX, ANSYS) - Mentoring - https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/783fcafc-9557-46dd-b54a-baa5a7432633/200105-F-XJ735-1005.jpg Work Experience - Mechanical Engineer II [INSERT DESCRIPTION OF ROLE] - Mechanical Analysis - Software Tool Development - Supporting Customer https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/dbc8af55-079a-4972-92c4-ad91f5f01a98/trends-3d-printing-at-scale.jpg Work Experience - ??? ??? https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603060909284-TW3ESH78J6QBPEIOLZDB/Banner.png Work Experience https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/6f359d8e-9060-42ce-861f-f2e51d31f4b8/DED+Project+Clip+1+%28Lowish+Res%29+%28Loop+Forever%29+%28Reduced%29.gif Work Experience https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/6f359d8e-9060-42ce-861f-f2e51d31f4b8/DED+Project+Clip+1+%28Lowish+Res%29+%28Loop+Forever%29+%28Reduced%29.gif Work Experience https://www.zachary-howell.com/academic-projects daily 0.75 2024-01-10 https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1576301144113-520PM6FWZ1NQQPYEH8ZW/20191205_132732.jpg Academic Projects Team GRATR (left-to-right): Zachary Howell, Adam Hugo, Kyle Barras https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1576316343515-9EA4YHO9HT52TQ9RXQ6Q/Poster.jpg Academic Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1576313553098-RZWE3ZN5I693NTNFN7R3/cad.jpg Academic Projects https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1576313497532-70NALPOYNLAADH7L9MZ7/side+cad.PNG Academic Projects 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Home https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1576313190465-6XK39GH0DZ1QZTG58BOA/Bridge+Drawing+Sheet4.PNG Home https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1603060909284-TW3ESH78J6QBPEIOLZDB/Banner.png Home https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1588955630201-497PNBA6J7F4OGYWN59B/Animation+2+%281%29.gif Home https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/e40bfcaa-afa7-477e-848d-4cce65e8c385/laser_with_film_grain_2000x1000.jpg Home https://www.zachary-howell.com/about-me daily 0.75 2024-05-10 https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/e0fff9fa-6c33-468a-92a1-319dd73ecf6f/blue-laser.png About Me - Work In my most recent professional venture, I worked as an R&D Mechanical Engineer at Essentium - an additive manufacturing startup headquartered in Austin, Texas. While there, I immersed myself in a wide range of fascinating projects, using my engineering know-how to tackle difficult problems and seizing any opportunity I could to grow professionally. At the core of my responsibilities was the development of a novel blue laser-based metal 3D printer - a key deliverable within a multi-million dollar DOD/AFRL defense contract. As I embark on the next phase of my engineering journey, I carry with me a skillset honed by my professional, academic, and personal endeavors. I am truly excited to channel these skills into a full-time mechanical engineering position within a forward-thinking, exciting team. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/1580448679073-VLGIJ0TO8WK4KY0YM776/1.2%28edited%29.png About Me - My name is Zachary Howell. I’m a mechanical engineer. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/38a6f810-bb4f-4abe-97a4-fbb701ad68ef/Climbing+Photo.jpg About Me - Play Beyond the world of engineering, you'll find me exploring the great outdoors, from backpacking and hiking to biking, disc golf, skiing, and climbing. My passion also extends to the world of music, as I enjoy playing a number of instruments and love finding new vinyl to spin. https://images.squarespace-cdn.com/content/v1/5df416358ef2d173adcc9791/87c61b8f-957d-45f6-b711-6bad88d96193/NASA2.png About Me - Origin Story Fueled by a childhood fascination with how things work, I embraced a love for STEM at an early age and ultimately discovered that engineering held my key to making a meaningful impact on the world. My journey led me to earn a B.S. in Mechanical Engineering from Colorado School of Mines, where I curated a unique blend of courses that netted me an Area of Emphasis in Aerospace Engineering. https://www.zachary-howell.com/new-page daily 0.75 2024-08-13