MECHANICAL SYSTEMS // ROBOTICS // MANUFACTURABLE DESIGN

ALEX LU
ROBOTICS SYSTEMS HARDWARE

Mechanical engineering student focused on robotics, product development, and manufacturable mechanical systems. Interested in subsystem design, packaging, validation, and turning concepts into reliable hardware.

Robotics systems, mechanism design, and electromechanical packaging

Product development, validation, DFM, and supplier coordination

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FOCUS

ROBOTICS + PRODUCT DEVELOPMENT

LOCATION

IRVINE, CA

AVAILABILITY

INTERNSHIPS / ENGINEERING ROLES

SYSTEM SNAPSHOT

TEAM LEADERSHIP

12 PERSON MECHANICAL SUBTEAM

PRODUCT PROGRAM SCALE

$300K+ HARDWARE PROGRAM

COMPETITION RESULT

18TH PLACE GLOBALLY AT URC

ABOUT

SYSTEMS OVERVIEW

I work at the intersection of robotics, product engineering, and manufacturing. My projects emphasize mechanism architecture, tolerance-aware design, subsystem packaging, structural validation, and execution under hard constraints. The goal is simple: build hardware that is credible on paper, manufacturable in practice, and reliable in deployment.

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PRIMARY DOMAINS

Robotics systems, electromechanical packaging, mechanism architecture, DFM, validation, and manufacturing execution.

WORKING STYLE

Systems-oriented, detail-conscious, and comfortable translating concept work into manufacturable hardware under schedule pressure.

Alex Lu

PROFILE

Mechanical engineering student based in Irvine, California.

PROJECTS

Selected Engineering Case Studies

Selected case studies showing subsystem ownership, validation methods, packaging constraints, and measurable outcomes.

2026 Mars Rover

URC-26

2026 Mars Rover

FIELD TESTED

2026 // Robotics Systems

University Rover Challenge platform focused on drivetrain, manipulator architecture, thermal packaging, and rapid integration under competition deadlines.

SYSTEM INTEGRATIONMASS OPTIMIZATIONTHERMAL MANAGEMENT

10-person subteam

~5 kg mass reduction

18th globally

2024 Competition Robot

FRC-24

2024 Competition Robot

COMPETITION READY

2024 // High-Speed Mechatronics

Crescendo robot with swerve drive, variable-angle shooter, rapid intake, and endgame mechanisms packaged for autonomous scoring reliability.

MECHATRONICSPACKAGINGSTRUCTURAL DESIGN

15 ft/s swerve

0.2 s elevator cycle

125 lb system

2023 Competition Robot

FRC-23

2023 Competition Robot

COMPETITION READY

2023 // Manipulator Architecture

Charged Up robot with rack-and-pinion arm geometry, piston-assisted extension, and robust multi-game-piece handling for repeated match loads.

DRIVEBASEARM DESIGNVALIDATION

17 ft/s swerve

80 deg arm travel

Multi-piece intake

2026 Rover Manipulator Arm

ARM-26

2026 Rover Manipulator Arm

COMPETITION-FOCUSED REDESIGN

2026 // Mechanical Systems

A task-focused 4-DOF plus linear-axis rover manipulator built to replace a heavier 6-DOF arm. The redesign reduced reach, simplified actuation and packaging, and freed weight budget while still covering the competition task space.

MANIPULATORWEIGHT REDUCTIONTASK-FOCUSED DESIGN

4 rotational DOF

~32 in reach

5 kg peak load

Antenna Rotator

ANT-00

Antenna Rotator

IN PROGRESS

2026 // Rover Communications

Temporary case-study scaffold for a rover-team antenna rotator built to maintain stronger long-range communication alignment during field operation.

COMMUNICATIONSTEMPORARYIN PROGRESS

Temporary page

Add CAD/media

Add field test results

WIP Battlebot Project

BOT-00

WIP Battlebot Project

IN PROGRESS

2026 // Combat Robotics

Temporary case-study scaffold for a work-in-progress battlebot project. Use this page to capture the design brief, weapon or drivetrain architecture, and testing outcomes as the build develops.

COMBAT ROBOTICSTEMPORARYIN PROGRESS

Temporary page

Add build photos

Add test results

Automatic Camera Film Scanner

FILM-00

Automatic Camera Film Scanner

IN PROGRESS

2026 // Imaging Hardware

Temporary case-study scaffold for an automatic camera film scanner focused on transport, illumination, alignment, and repeatable frame capture.

IMAGINGTEMPORARYIN PROGRESS

Temporary page

Add mechanism photos

Add scan output

Custom Keyboards

KEY-00

Custom Keyboards

IN PROGRESS

2026 // Product Engineering

Temporary case-study scaffold for custom keyboard work, including product architecture, DFM, manufacturing coordination, and release outcomes.

DFMPRODUCTTEMPORARY

Temporary page

Add production data

Add photos

Cosplay Props

COS-00

Cosplay Props

IN PROGRESS

2026 // Fabrication / Props

Temporary case-study scaffold for cosplay prop builds, including concept translation, fabrication, finishing, and practical wear or handling considerations.

FABRICATIONTEMPORARYIN PROGRESS

Temporary page

Add build photos

Add finished results

Photography + Cinema Grip Lighting Tools

GRIP-00

Photography + Cinema Grip Lighting Tools

IN PROGRESS

2026 // Studio Tools

Collection page for small 3D-printed photography and cinema grip tools made to solve quick workflow problems around the studio.

3D PRINTINGSTUDIOIN PROGRESS

Temporary page

Add tool photos

Add studio use notes

Carbon Fiber Forging Experimentation

CF-00

Carbon Fiber Forging Experimentation

IN PROGRESS

2026 // Materials Experimentation

Temporary case-study scaffold for carbon fiber forging experiments focused on tooling, process variables, part quality, and practical fabrication lessons.

COMPOSITESTEMPORARYIN PROGRESS

Temporary page

Add process photos

Add test observations

EXPERIENCE

Program Execution And Team Leadership

Engineering and product roles centered on system integration, technical leadership, and getting hardware into the field.

ROBOTICS PROGRAMS

SEP 2025 - PRESENT

Mechanical Lead

SC Robotics

Lead a 10-member mechanical team developing a Mars rover platform for the University Rover Challenge.

Own drivetrain, manipulator, and full-system architecture while coordinating integration with electrical and software leads.

Redesigned the arm and wrist system using SolidWorks FEA to remove approximately 5 kg while improving structural confidence.

Introduced a wrist differential and linear-rail mechanism inside a five-day deadline to expand usable range and satisfy submission requirements.

Implemented a modular electronics bellypan with sealed enclosures plus active and passive cooling to improve thermal management during field testing.

SEP 2022 - MAY 2024

Mechanical Member

FIRST Robotics Team 6560

Designed drivebase architecture and bellypan packaging to improve system integration and support repeatable autonomous behavior.

Developed an extending arm and 4-bar intake with impact resistance informed by FEA and repeated match loading.

Integrated vision hardware into the mechanical package to support autonomous targeting performance.

Led outreach activity that secured $30K in sponsorship support through cold calling and in-person events.

PRODUCT ENGINEERING

AUG 2022 - AUG 2025

Product Engineer

Paramount Keeb

Launched the Ciel and Ciel65 keyboard series from concept to production, shipping 2,000+ units and generating $300K+ in revenue.

Released manufacturing-ready SolidWorks packages with assemblies, engineering drawings, and GD&T to hold critical fits to +/-0.05 mm.

Managed qualification testing and finish control across aluminum, brass, and polycarbonate parts, reducing finish defects by 15%.

Executed five major production runs across multiple suppliers, owning RFQs, qualification, DFM, QC, and manufacturing coordination.

EDUCATION

JUN 2024 - JUN 2026

Mechanical Engineering

Irvine Valley College

4.0 GPA in the Honors Program.

Focused on mechanical systems, manufacturing, and engineering analysis.

Applied coursework directly through robotics, fabrication, and product development work.

TECHNICAL SKILLS

Tools, Analysis, And Manufacturing Capability

Tools and methods used across CAD, analysis, manufacturing, and cross-functional execution.

CAD / ANALYSIS

SolidWorks

Creo

Fusion 360

ANSYS

SolidWorks FEA

AutoCAD

GD&T

SOFTWARE / CONTROLS

Python

C++

C

Java

MATLAB

LabVIEW

Git

Excel

BUILD / MANUFACTURING

CNC

3D Printing

Rapid Prototyping

Composite Design

Additive Manufacturing

Subtractive Manufacturing

Electrical Wiring

Systems Integration

CONTACT

Ready For The Next Program

Open to defense-tech, robotics, aerospace, and product engineering opportunities where mechanical systems execution matters.

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DIRECT CHANNEL

EMAIL

[email protected]

LOCATION

Irvine, California

FOCUS

Robotics, aerospace-adjacent systems, and manufacturable product hardware.