Formlabs

Manufacturing Engineer

2021–Present

2026

Recommended by the COO for a temporary role rotation to lead end-to-end implementation of a high volume dental aligner production workflow using Form 4L printers along with specially developed software and material solutions at a Mexico based production facility
Debugged three critical technical issues during onsite pilot (CPU thrashing, file overwrite, print adherence)
Coordinated multidisciplinary work to make customer specific modifications (print settings changes, material modifications) while decreasing print time, improving part accuracy, and increasing packing density

Dentsply Mexicali aligner manufacturing workflow, from print to finished aligner

Developed a structured template for NPI readiness by each product development phase. Adopted by each of four new generation NPI programs
Improved F4L BP Flex yields from ~70% to >99% through CNC DFM review

Owned Form 4L backlight module product realization
Reduced LCD potting proudness failure rate from 18% to 2%, saving $300k annually
Sourced automation solution increasing resin cartridge RFID programming by 50%
Brought Form 4 and Form 4L BLU and LCD lines to stable mass production with 500k+ annual savings

Featured In

Form 4 Formlings: Under the Orange Hood Formlabs engineering blog on the team behind Form 4

F4L BP Flex F4L LCD Module F4L Backlight Module

Responsible for the manufacturing development of three core user replaceable subsystems

Promotion to Manufacturing Engineer II
Owned Form 4 backlight module product realization
Managed schedule and technical readiness from quote through pre-production to mass production ramp
Designed, built, tested three fixtures for optical testing
F3L tank V3: improved from 87% to 91% print success, yields from 90% to >99%
Supported second sourcing and Vietnam mold transition cost downs for F3 resin tanks

Form 4 Backlight Unit. Engineered to supply collimated UV light to the print plane while maximizing optical power uniformity

Owned sustained production of eight product lines (20 million dollars annual production)
Managed intern on projects including change tracking dashboard, measurement jig development, test fixture validation
Created live updating commodities usage tracking dashboard
Initiated ECO implementation reporting process across primary contract manufacturers
Spearheaded F3L tank yield improvement project yielding 700k annual scrap cost savings

Provided manufacturing support for tank products and print success metrics
Redefined quality and traceability standards for PMP film
Established JIRA project communication with contract manufacturing
Guided Wash and Cure L products through technical issues from PVT through mass production ramp
Built and tested jigs for laser module production