Patrick Chang’s Portfolio (Unabridged)

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Patrick Chang - Resume.pdf

Patrick Chang - Portfolio.pdf

<aside> <img src="/icons/link_blue.svg" alt="/icons/link_blue.svg" width="40px" /> LINKS

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Patrick Chang’s Website

Patrick Chang’s Resume (Unabridged)

<aside> 🎮 BACKBONE PRO Backbone Labs 04/2024 → Now

Backbone Pro: Owned design of several modules of the Gen 1 Backbone Pro, starting from late Proto, through EVT, DVT, PVT, and Ramp, in a rapid development sprint lasting 12 months.

D-Pad: Designed the D-pad plastic (triple-shot, injection-molded PC-ABS) and carbon-pill membrane (compression-molded rubber silicone). Worked with ID and UXR cross-functional teams to determine optimal shape, texture, and force-displacement profile.
Face Buttons: Designed all eight face buttons (ABXY, Backbone, Menu, Option, and Capture), including the plastic (double- and triple-shot injection molded PC-ABS), membranes (compression-molded rubber silicone), and metal dome switches.
PCB’s: Owned mechanical design of all nine PCB’s, including defining the mechanical control outline (MCO), button locations, connector locations, and keep-out zones. Worked with the cross-functional teams to test and pass regulatory compliance (EMI and ESD).
Bluetooth Antenna: Owned mechanical design, assembly, and routing of the custom antenna component. Drove design of the antenna assembly process, tools, and fixture at FATP.
System Wiring and Interconnects: Owned wire-routing of all cables and interconnects, including working with suppliers to design a custom USB-C cable, connectors, and wire-routing die-cuts.
Build Support and Management: Travelled to suppliers in China to oversee assembly line bring-up and qualification during EVT, DVT, and PVT. Triaged assembly issues, performed DOE’s, and performed failure analysis during reliability testing.
Other Product Design Work: Design of the detachable pad magnetic system, critical stacks, tolerance analysis, Cp/Cpk, FAI/SPC’s, DOE’s, EFFA, and project management.

Project Page: Backbone Pro (If the link above says “No Access,” please contact me directly if you need access.)

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<aside> ⚡ N1 CHARGER GENERATION 2.0 DESIGN Neuralink 07/2021 → 04/2023

I lead mechanical design of the production version of the N1 Charger for use in Neuralink’s first human clinical trials. Challenges included:

Developing early prototypes while optimizing design for safety, comfort, and human factors for members of the SCI and paraplegic community.
Owning full design and production of the N1 Charger Coil, including creating drawings and BOMs, determining tolerances, selecting colors and materials, working with vendors, ordering parts, and producing chargers.
Overseeing lifecycle maintenance, owning iteration and improvements, and managing the charger team.
Navigating documentation and testing during the FDA approval process.

Project Page: ‣ (If the link above says “No Access,” please contact me directly if you need access.)

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<aside> 🏭 N1 CHARGER MANUFACTURING Neuralink 01/2022 → 04/2023

I developed Neuralink’s in-house production line for the N1 Charger in both Fremont, CA and Austin, TX. Challenges included:

Setting up a first manufacturing space in Fremont, CA.
Planning and setting up a larger, linearized assembly line in Austin, TX.
Managing parts inventory and the fleet of chargers in the field.
Providing documentation for the FDA approval process.
Implementing a manufacturing execution system (MES) and a kit-based manufacturing process.
Aiding the implant manufacturing team in de-risking large changes to their manufacturing line in preparation for an FDA audit.

Untitled

Project Page: ‣

(If the link above says “No Access,” please contact me directly if you need access.)

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<aside> 🐷 N1 CHARGER GENERATION 1.5 DESIGN Neuralink 03/2021 → 03/2022

I worked on a team to triage problems with the Rev 1.0 charger for use in Phase 1 FDA testing. Challenges included:

Uncovering major technical issues with the Rev 1.0 charger through rapid testing.
Designing and building several new prototypes (dubbed Rev 1.5 chargers).
Implementing daily iteration cycles for testing and feedback.
Developing a biocompatible adhesive for use on animals.
Designing and producing a stable charger version (Rev 1.6) to support testing for the 18 month testing cycle.

Project Page: ‣

(If the link above says “No Access,” please contact me directly if you need access.)

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<aside> 🧠 N1 CHARGER GENERATION 1.0 DESIGN Neuralink 09/2020 → 03/2021

I worked on a team of three engineers to develop Neuralink’s first wireless charger. Challenges included:

Early R&D of the charging technology to determine engineering feasibility.
Designing a modular enclosure for the first in-house charger.
Performing thermal testing and simulation to determine safe limits of use.
Modifying designs to support multiple internal development causes.
Preparing the charger for the 2020 Live Demo.

Project Page: ‣

(If the link above says “No Access,” please contact me directly if you need access.)

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<aside> ⚖️ TECHNICAL PATENT REVIEW AT IP Management 09/2023 → 12/2023

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<aside> 🛢️ VACUUM CHAMBER DESIGN FOR A METAL 3-D PRINTER *Nikon Research Corporation of America ***12/2017 → 3/2018

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<aside> 🚗 ROTARY STAGE FOR A METAL 3-D PRINTER Nikon Research Corporation of America 12/2018 → 03/2019

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<aside> 🌡️ NEXT GENERATION ROTARY PROBE HEAD DESIGN *Nikon Research Corporation of America ***07/2015 → 01/2016

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<aside> 📸 REAL-TIME VISION SYSTEM FOR A METAL 3-D PRINTER *Nikon Research Corporation of America ***02/2019 → 05/2019

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<aside> <img src="/icons/new-document_blue.svg" alt="/icons/new-document_blue.svg" width="40px" /> OTHER PROJECTS

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