ALEX LU
ROBOTICS SYSTEMS HARDWARE

Owned the design and development of multiple subterranean ROV subsystems, including a motor-driven self-righting gimbal with solenoid clutch/locking mechanism, propulsion-system improvements, and a redesigned electronics capsule.

Redesigned drill-related hardware, including an offset gearbox and drill motor section, improving packaging, reliability, manufacturability, and assembly while working within tight system-level constraints.

Took designs from CAD through fabrication, assembly, and testing using SolidWorks/Fusion 360, 3D printing, mill, lathe, drill press, tapping, and other shop processes; selected materials and manufacturing methods for prototype and field hardware.

Integrated mechanical and electrical systems through PCB/enclosure packaging, sensor mounting, harnessing, sealing, and field troubleshooting, iterating designs rapidly in a startup environment toward full-system testing.

Mentor the mechanical subteam on rover subsystem design, CAD review, manufacturability, and integration planning.

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

Owned 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.

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.

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.

4.0 GPA