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Hello There

I'm Kevin Chen

Mechanical Engineer
Maker
Artist.

Who am I?

A senior @ Northwestern University eager to tackle aerospace and sustainable engineering challenges. Beyond school, I am involved with wildfire prevention, soft materials & additive manufacturing research, rock climbing, and music production. My background is in mechanical design and machining techniques, stemming from my experiences from VEX Robotics, Materials Research, NASA Langley, and Sierra Space.

My Ambitions

The stars rise and set every night, constantly reminding the dreamer in all of us that there is something out there to discover. They served as shepherds for mankind, guiding explorers who yearned to understand what lies beyond since the invention of sails. Thus, humanity reached into the cosmos years ago to satiate our drive for discovery. Yet, ever since then, space has slowly seemed to drift further away, clouded by indecision and bureaucracy.

In recent years, new pioneers have reignited a desire to explore the stars. Infected by this vision, I want nothing more but to be part of the next generation of explorers. Moreover, I am confident that my previous experience will allow me to hit the ground running, but I also will embrace the adaptability and unwavering perseverance at the core of engineering. After all, what better way to improve life down on Earth than by making our mark in the heavens.

Skills

CAD & FEA Technical Shop Software
SOLIDWORKS Stress & Fracture Analysis Water Jet & Diamond-Edged Saw Python
NX Solid & Hybrid Propulsion Conventional & CNC Machining MATLAB
Creo Composite Fabrication Laser Cutting HTML & CSS
Ansys, Abaqus & Femap/NASTRAN PID & Odometry FDM & SLA 3D-Printing ImageJ & Phantom Camera Control

My Experience

JUNE 2023 - SEPTEMBER 2023

Stress Analysis and Manufacturing Intern

Sierra Space

In the summer of 2023, I worked at Sierra Space as a stress analyst and manufacturing engineer. In those 12 weeks, I assessed Dreamchaser subsystems for structural health using FEMAP NASTRAN as a part of the final test campaign before its inaugural launch in 2024. I also devised and presented revised thermal margins for the external cargo mounting interface in conjunction with NASA ISS mating team as Sierra’s responsible engineer. In manufacturing, I conducted purging operations and X-ray inspection for the peroxide and kerosene tanks before orbital welding and final vehicle integration.

JUNE 2022 - SEPTEMBER 2022

NASA Academy Intern

NASA Langley Structural Dynamics

As the youngest intern accepted into the 2022 Academy team, I jointly collaborated with Langley's structural dynamics department and the Academy's undergraduate team. Specifically, I conducted flexural testing of Advanced Composite Solar Sail System (ACS3) composite booms, and assisted in cube-sat assembly and deployment tests. This mission is set to launch in December aboard a Rocket Lab Electron vehicle. I also designed crushable hybrid composite-polymer structures to improve passenger safety aboard new experimental VTOL aircraft. A large scale gantry crash test was completed in the fall of 2022, where these absorbers and test article successful completed a trial in the validation process.

May 2021 - June 2022

Undergraduate Researcher

Northwestern University Bazant Materials Laboratory

I worked in the Zdeněk Bažant Material Science lab as an undergraduate researcher in 2021. My objective during this period was to design and develop a biaxial test frame to perform fracture analysis on various composites. This data would be used to determine material properties to better inform manufacturers as composites become increasingly relevant within the aerospace and automotive industries. I also was tasked with machining specimens using conventional and CNC mill, lathe, diamond-edged bandsaw, and waterjet. These opportunities allowed me to hone my skills in SOLIDWORKS, stress analysis through Abaqus, and also gain certification for operating shop machinery. Further publications are pending as well.

March 2021 - Present

Lurie Inventor

Ann & Robert H. Lurie Children's Hospital of Chicago

I am currently collaborating with Lurie Children’s Hospital to certify an improved infant transportation device developed alongside 2 other students. This system, the X - Strap will replace their aging restraining straps that possess numerous safety flaws. Through a school-wide research and design course during the 2020-2021 school year, our group was the sole team to be selected to continue our partnership with a client.

August 2017 - May 2020

VEX Robotics Team, 7701X

Lead Designer and Builder

I joined our school’s robotics club as a sophomore, a year later than most of my peers, but it quickly became my primary commitment to make up for lost time. My 3 years of experience in VEX Robotics have armed me a toolbox of skills. On my team, I took on the role of our main chassis assembler and drive coach. Additionally, I gained substantial experience in PID control loops, odometry, inertial sensors, and pneumatics, while also leveraging my knowledge in mechanical design and and building techniques. This expertise led our team to claim numerous titles including World Championship Divisional 1st place (2x), 2019 1st place World Driver Skills Ranking, VEX Robotics 2020 National Signature Event Tournament Champion, Regional Tournament Champions (8x).

Feb 2022 - Present

InfernoGuard USA

Environmental Data Lead

As the Environmental Data Lead at Infernoguard, I investigate markers indicating the presence of wildfires (particulates, humidity, modified combustion efficiency). Our team is currently working to generate a predictive algorithm to estimate distance and severity of fire from point of interest. My other duties include coordinating with backend, hardware, and leadership regarding how data can be applied to product or software improvements. Most recently I have been organizing testing proposals to be presented to potential clients for future and ongoing controlled burn testing. In total, Infernoguard has been awarded over $500,000 across multiple fundraising competitions.

September 2020 - June 2022

NUSolar & Northwestern Formula Racing

Chassis Team Member

During my time with the NUSolar and Formula Racing teams at Northwestern, I assisted the manufacturing of Solar Car 7. I also contributed to the development of the Solar Car 8 floorboard using NX and Abaqus FEA as an independent project with NUSolar leadership. Specifically, I specialized in composite fabrication, water jet cutting, and laser cutting for the current Formula vehicle.

Portfolio

See My Latest Projects.

Below, you will find some of my past and ongoing projects that I have lead or had a hand in.

Sierra Space

Stress Analysis and Manufacturing

At Sierra Space, I was the responsible engineer tasked with ensuring structural health of avionnics, communications, and environmental control systems of the Dream Chaser spaceplane during the Sine-Vibration test campaign. These batteries of evaluation function as the final checkoffs before final vehicle intergration before launch. As a fluids manufacturing engineer, I also worked closely with the integration of the propulsion feed system, owning several pieces of documentation regarding the installation of the forward and aft thruster isolation assemblies.

Autonomous RC Plane

Anvil Arrow Path Routing

My most recent personal project has been the design and drafting of a RC Plane inspired by the Anvil Arrow from the Star Citizen IP. Employing NX and Inventor Sheet Metal, I created a foamboard body and drawing to enable flow modeling of the plane in Ansys Fluent CFD to obtain a lift:drag ratio of 13.1:1, sufficient for protoflight. We are also writing a fully autonomous flight algorithm with waypoint and GPS tracking capability. Paired with LQR control theory for flight stability and odometry for position referencing between GPS updates, the plane can accurately fly pre-programmed routes.

NASA Langley 2022

Design and analysis

Pictured above are several of the projects I worked on at NASA Langley Research Center. My primary goal was to design and 3D-Print crushable geometries to improve occupant safety during VTOL aircraft crashes. 30-ft drop tower testing is pictured on the left. I also dealt with a variety of photogrammetry applications, depicted in the speckle-painted lift-cruise frame. Later on, I was heavily involved with the folding and flexural testing of ACS3 composite booms and its solar sails.

NASA Langley 2022

Testing environments

Langley is home to the Landing and Impact Research Facility, a testing gantry responsible for the evaluation of craft like the Apollo Lunar Lander and the SpaceX Dragon 2 Capsule. It continues to be a keystone within spaceflight, specifically through its role in testing of Mars Sample Return components. Pictured above is our team validating IMU data from a heatshield demonstration unit designed to protect Martian samples during atmospheric reentry. We designed and constructed the collapsable drop tower shield on the right for smaller scale hanger-based testing of elements not suitable for gantry use.

VEX Robotics

Team 7701X

A few moments captured after at several tournaments including Worlds and the US Signature Event.

VEX Robotics 2020

Tower Takeover

The objectives of the 2020 season, Tower Takeover, was to capture cubes, stack them in zones, and deposit them in towers located around the field. After multiple iterations of refining our robot over the year, we were effectively able to score more points at a faster pace than most if not all of the other teams in the world. We secured 1st place in our division during the 2020 World Championships, ended as divisional finalists, and won the national signature event (the second largest competition in the world).

VEX Robotics 2019

Turning Point

The 2019 game, Turning Point, entailed picking up and launching balls at acrylic flags, flipping and placing caps onto raised poles, and a platform climb at the end of the match. Our choices regarding mechanical design and autonomous programming allowed our team to remain undefeated and secure 1st place in our division during the 2019 World Championships.

Materials Research

Bazant Laboratory

Here are some additional details regarding my work at the Zdeněk Bažant Material Science lab as an undergraduate researcher in 2021.

X - Strap

Medical Device Design

A written report regarding the X - Strap can be found here.

Confocal Microscopy

Stark Neuroscience

As an intern during the summer of 2017, I was the only freshman to be admitted to Indiana Project STEM out of 100 accepted students. During that summer I worked at Indiana University's Stark Neuroscience Research Center and explored the characterization of Central Amygdala neurons and their potential role in pain-related behavior. In the following summers, I remained in my previous lab where I had established a strong foundation operating confocal microscopes and other wet lab machinery. I concluded my research with a poster presentation that placed me 1st in my ISEF Regional Science Fair and was also the recipient of a 2019 American Psychological Association Award. We are currently in the final stages of review for a paper that I have co-authored in the Journal of Comparative Neurology.

Journal

A few more things.

Rock Climbing

Following a trip to the Huangshan, a nearly 2 kilometer tall mountain range in China, I managed to conquer the greatest phobia I had, the fear of heights. Although the methods were ones of brute force (I bawled the entire way up), it dawned on me that no challenge I would encounter in the future would be as hard as ascending those steep cliffs. This event is what led me to pursue rock climbing, an activity that I wholeheartedly avoided in the past, but now would demonstrate if I had truly overcome my fear. I had not — not entirely. That was 6 years ago, and I am climbing to this day. I most recently scaled Long's Peak in 2023, a bucketlist 14er in Colorado.

Music production

I fell in love with music twice. Once while I was learning the Alto Saxophone in middle school, and once this past year after listening to Kanye West's 5th studio album, "My Beautiful Dark Twisted Fantasy." Upon my first listen, I had yet to comphrehend the scope of its vivid soundscape accompanied by many profoundly personal lyrics, but I knew I had never heard anything like it before. I then found myself diving head first into music and learning how it is mixed and produced. Linked below are some original pieces and covers I have creating using Cakewalk by BandLab.

Art

Drawing and painting have always been a pastime for me. It acts like a medium between reality and my perception of the world. I've also learned to use art to visualize concepts difficult to communicate in text. I find this method extremely effective when demonstrating mechanical systems in engineering.

Butters

After I left for college, my parents decided that they had to fill the void in the home with something. So we adopted a dog — her name is Butters. We soon learned that fostering a puppy is a full time job, for 3 people. In the two years we have had her, I've learned countless lessons, but now I know to prepare for more.

Contact

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Phone

Phone: (+1) 317 523 0206
Mobile: (+1) 317 918 4659

Email

kevinchen2024@u.northwestern.edu

Address

6541 Abby Lane
Zionsville, IN
46077 US