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Patrick Chang - Resume.pdf

Patrick Chang - Portfolio.pdf

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Patrick Chang’s Website

Patrick Chang’s Portfolio (Unabridged)

<aside> <img src="/icons/video-game_blue.svg" alt="/icons/video-game_blue.svg" width="40px" /> BACKBONE LABS Atherton, CA

Senior Product Design Engineer 04/2024 → Today

• Backbone Pro: Designed several modules on the first generation Backbone Pro mobile game controller, starting from late Proto, through EVT, DVT, PVT, Ramp, and EFFA 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 the 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 and connector locations, and keep-out zones. Worked with the cross-functional teams to test and pass regulatory compliance (EMI, ESD, and OTA).
  • Bluetooth Antenna: Owned mechanical design, assembly, and routing of the custom antenna component. Drove design of the assembly process, tools, and fixture for the antenna 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, qualification, and reliability testing during EVT, DVT, and PVT. Triaged assembly issues, performed DOE’s, and performed failure analysis.
  • Other Product Design Work: Performed other product design work, including design of the detachable pad magnetic system, development of critical stacks, tolerance analysis, analyzing Cp/Cpk, FAI/SPC’s, managing DOE’s, and even project management. </aside>

<aside> <img src="/icons/judicial-scales_blue.svg" alt="/icons/judicial-scales_blue.svg" width="40px" /> AT IP MANAGEMENT Taipei, TW

Mechanical Engineering Consultant (Part-Time) 09/2023 → 12/2023

• Patent Analysis: Reviewed a Fortune 500 company’s patent portfolio in the electro-encephalography (EEG) and exoskeleton spaces in order to identify high-value patents. Performed market research in these industries to identify potential collaborators, licensees, buyers, and infringers. </aside>

<aside> <img src="/icons/brain_blue.svg" alt="/icons/brain_blue.svg" width="40px" /> NEURALINK CORPORATION Fremont, CA

Mechanical Engineering Lead 12/2019 → 04/2023

• N1 Charger Mechanical Design: Owned all mechanical design, manufacturing, testing, and documentation of the N1 Charger, Neuralink’s wireless charger for its N1 Brain Implant.
  • Owned all mechanical design. Tasks included rapid prototyping, working with industrial designers, creating PCB layouts, thermal testing, iteration, detailed design, and generating production drawings using GD&T.
  • Managed all Verification & Validation (V&V) testing for the charger, including developing test protocols, designing test fixtures, supporting animal testing, and managing 3rd party testing for basic safety (IEC 60601-1), shock and vibration (IEC 60601-1-11), and biocompatibility (ISO-10993-1).
  • Performed all engineering documentation for the charger during the FDA approval process, including writing system specifications, developing user needs and requirements, performing FMEA, and generating BOM’s.
• N1 Charger Manufacturing: Developed Neuralink’s first, in-house production line for the N1 Charger.
  • Set up an initial manufacturing space in Fremont, CA that supplied >200 chargers for technical development, V&V testing, investor demos, and animal studies.
  • Set up a linearized assembly line in Austin, TX. Tasks included mapping production flow, designing and building manufacturing fixtures, generating station layouts, building the line, writing SOP’s, developing incoming test and cleaning practices, validating the line, and performing line balancing and timing diagrams.
  • Managed charger production, including creating BOM’s, managing build requests, managing inventory and vendor supply-chains, and developing a manufacturing tracking system.
• N1 Implant Support: Supported N1 Implant development, including developing a test setup for mechanical impact testing and conducting in-vivo thermal modeling of the N1 Implant in COMSOL. </aside>

<aside> <img src="/icons/camera_blue.svg" alt="/icons/camera_blue.svg" width="40px" /> NIKON RESEARCH CORPORATION OF AMERICA Belmont, CA

Senior Mechanical Engineer 07/2016 → 11/2019

• Electron-Beam Metal 3-D Printer: Lead mechanical design and prototype of the build stage and powder supply systems for a novel electron-beam, metal, 3-D printer.
  • Designed and prototyped proof-of-concept powder stages that could operate at temperatures up to 1000 °C, had 10 μm step resolution, and contained active temperature control.
  • Developed a powder supply and raking system capable of achieving spread uniformity less than 50μm and faster than 1 sec build layers.
  • Designed and assembled the vacuum system for testing the 3-D printer at high to ultra-high vacuum, including developing system specifications, designing the chamber, and selecting all chamber accessories.
• Directed Energy Deposition (DED) Metal 3-D Printer: Explored improvements to the Lasermeister 100A metal 3-D printer. Worked with optical engineers to design an optical imaging system for real-time measurement of melt temperature, beam shape, and powder flow rate. Performed experiments to characterize the effects of move speed, laser power, build direction, powder flow rate, and oxygen content on build quality.

Mechanical Engineer 11/2014 → 07/2016

• Fully Wireless Wafer Stage. Helped design a fully wireless wafer stage that removes tubes and wires from the stage.
  • Investigated tubeless cooling via the use of evaporative cooling through porous ceramic.
  • Designed, prototyped, and validated a wireless power system utilizing supercapacitors that was capable of 50W/20A currents and rapid recharge cycles as low as 1.2 seconds.
  • Developed a wireless linear position sensor using an array of hall effect sensors. Validated the system to a measurement repeatability <20 µm. Co-authored a patent (US Patent No. 20180205305).
• Rotary Probe Head: Developed a novel, “dual-head” rotary probe measurement tool for Nikon CMMs. This concept allows a single probe head to mount two measurement devices simultaneously for rapid in-vivo measurement or to accommodate larger payloads via the use of detachable counterweights (US Patent No. 10,107,654).

Test Engineer 11/2012 → 11/2014

• Test Engineering and Lab Management. Provided test support for three of NRCA’s laboratory spaces. Tasks included performing modal testing, writing automation scripts for test equipment, conducting experiments, enforcing general lab safety, maintaining laboratory cleanliness, and tracking test equipment.
• Planar Motor Testing and Manufacturing Bring-Up. Helped bring-up manufacturing of a custom-built motor for Nikon’s next generation lithography wafer stage. Specific tasks include assembling units, training technicians, developing manufacturing testing criteria and protocols, building test fixtures, and writing test scripts in C# and MATLAB.
• Next Generation Wafer Bonding. Worked on the design and analysis of a next generation clamping system for 3-D chip production. Co-authored a patent for a novel precision clamp based on the research results (US Patent No. 10,259,104). </aside>

<aside> <img src="/icons/lock_blue.svg" alt="/icons/lock_blue.svg" width="40px" /> SANDIA NATIONAL LABORATORIES, LIVERMORE, CA Livermore, CA

Member of the Technical Staff 11/2011 → 04/2012

• Integrated Security Systems. I worked on a multidisciplinary engineering team to maintain and upgrade the nuclear stockpile. Tasks included designing and prototyping upgrades to mechanical systems to replace aging or outdated ones. </aside>

<aside> <img src="/icons/library_blue.svg" alt="/icons/library_blue.svg" width="40px" /> GEORGIA INSTITUTE OF TECHNOLOGY Atlanta, GA

Graduate Research Assistant Advised By Dr. David Rosen 08/2008 → 07/2011

• Master’s Thesis: Researched a novel, FEA-based optimization algorithm for the design of highly-complex truss topologies (10,000+ truss elements). Successfully decreased optimization time from >24 hours to <1 min relative to competing multivariable optimization methods.

Graduate Teaching Assistant 11/2009 → 04/2010

• ME3057: Experimental Methods Laboratory: Managed two, senior-level mechanical engineering laboratory courses, each with 30 students. Specific tasks include introducing students to experimental methodology and best practices, setting up and running weekly lab experiments covering various engineering topics, grading reports, and enforcing general lab safety. </aside>

<aside> <img src="/icons/graduate_blue.svg" alt="/icons/graduate_blue.svg" width="40px" /> EDUCATION

• M.S. in Mechanical Engineering *Georgia Institute of Technology, Atlanta, GA ***09/2008 → 06/2011 GPA: 3.87

• B.S. in Mechanical Engineering *Georgia Institute of Technology, Atlanta, GA ***09/2004 → 06/2008 GPA 3.85 </aside>

<aside> <img src="/icons/official-document_blue.svg" alt="/icons/official-document_blue.svg" width="40px" /> PATENTS

Active

• Chang P.S., Pharand, M., Rosa, M., Wells, J.K., & Reynoso-Mora, P. (2019). Actuator Assembly Including Magnetic Sensor System for Vibrationless Position Feedback (U.S. Patent No. US10451982B2). U.S. Patent and Trademark Office. URL
• Chang, P.S., Rosa, M.D., Marquez, J.A., Pharand, M. (2018). Rotary Probe Head (U.S. Patent No. US20170059296A1). U.S. Patent and Trademark Office. URL
• Hashemi, F.A., Bow, T.D., Chang, P.S. (2019). Precision Clamp (U.S. Patent No. US10259104B2). U.S. Patent and Trademark Office. URL

Inactive

• Goodwin, E.P., Marquez, J.A., Binnard, M.B., Herr, B., Bjork, M.P., Coon, P.D., Chang, P.S., & Ishikawa, M. (2018). *Additive Manufacturing System with Rotary Powder Bed (*U.S. Patent No. US20200346407A1). U.S. Patent and Trademark Office. URL
• Rossi J.P., Jeong, Y.J., Chang, P.S., Marquez, J.A., Phillips, A.H., Guo, L., (2022). Powder Supply Assembly for Additive Manufacturing System (U.S. Patent No. US20220266345A1). U.S. Patent and Trademark Office. URL
• Phillips, A.H., Choi, Y.J., Guo, L., Smith, D.G., Binnard, M.B., Tyminski, J.K., Goodwin, E.P., Marquez, J.A., Herr, B.W., Bjork, M.P., Chang, P.S., Ishikawa, M., Coon, P.D. (2020). Selective Sintering and Powderbed Containment for Additive Manufacturing (WIPO Patent No. WO2021003309A3). World Intellectual Property Organization. URL
• Phillips, A.H., Chang, P.S., Binnard, M.B., Rosa, M.D., Ketsamanian, S., Guo, L., Herr, B.W., Goodwin, E.P., Marquez, J.A., Bjork, M.P., M., Coon, P.D., Ishikawa, M. (2020). Non-Coaxial Rotating Turntables for Additive Manufacturing (WIPO Patent No. WO2021003202A2). URL
• Goodwin, E.P., Durko, H.L., Smith, D.G., Marquez, J.A., Binnard, M.B., Chang, P.S., Bjork, M.P., Coon, P.D., Herr, B.W., Ishikawa, M. (2020) Metrology for Additive Manufacturing (WIPO Patent No. WO2021003444A2). URL
• Solidum, V.I., Sanford, K.D., Phillips, A.H., Guo, L., Chang, P.S., Marquez, J.A., Choi, Y.J. (2022) Powder Supply Assembly with Level Sensor and Multiple Stages with Refilling (U.S. Patent No. US20220305733A1). URL
• Chang. P.S., Marquez, J.A., Ketsamanian, S., Phillips, A.H., Rosa, M.D., Guo, L., Binnard, M.B. (2022) Material Bed Assembly for a Processing Machine (WIPO Patent No. WO2022150340A1). URL
• Phillips, A.H., Goodwin, E.P., Goldstein, G.L., Renwick, S.P., Binnard, M.B., Chang, P.S., Rosa, M.D., Wells, J.K. (2022) Systems and Methods for Improving Accuracy in Three-Dimensional Printing Processes (WIPO Patent No. WO2022192368A1). URL
• Chang. P.S., Rosa, M.D. (2022) Systems and Methods of Supplying Material to Additive Manufacturing System in Vacuum Environment (WIPO Patent No. WO2022197612A1). URL </aside>

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