Project Overview

As a Mechanical Design Engineer at Alcon for three years, I managed the lifecycle of next-generation intraocular lens and injector devices. My role primarily focused on human-centered design, rapid prototyping, and validation, ensuring devices met strict FDA standards.

Technical Contributions

Figure 1: Types of intraocular lenses I worked on
Figure 2: Delivery devices I worked on

1. Rapid Prototyping & DFM

Owned the concept-to-prototype pipeline for next-gen injector devices, from initial brainstorming to manufacture-ready designs.

  • Drove weekly iteration cycles of PTC Creo CAD and 3D-printed prototypes to rapidly test and refine concepts.
  • Down-selected concepts using Six Sigma tools (Pugh matrix) to converge on the strongest design direction with cross-functional buy-in.
  • Advanced the selected design into injection-molded prototypes and validated performance through bench testing and KOL/surgeon evaluations.
  • Partnered with manufacturing vendors on DFM analysis and tooling to ensure complex geometries molded consistently at scale.
  • Managed CAD data and released mass-production design documentation through PTC Windchill, maintaining version control and traceability from prototype to production.

2. Statistical Analysis & Validation

Moved beyond “pass/fail” testing by implementing statistical quality control using Minitab:

  • Defined delivery testing requirements and executed hypothesis testing (e.g., 2-sample % defective tests) to validate design changes against legacy standards.
  • Utilized statistical models to analyze failure rates, ensuring the final product met Six Sigma reliability requirements before transfer to manufacturing.

3. Cross-Functional Program Leadership

Served as core design-team member on the intraocular lens platform, acting as the technical link between marketing, legal, tech transfer, optics, manufacturing, and test teams.

  • Delivered new CAD design iterations on request to support cross-departmental test builds and evaluations.
  • Owned design documentation to maintain compliance with FDA design controls.

4. Human-Centered Design

Organized and led clinical studies with ophthalmic surgeons to refine device ergonomics.

  • Translated qualitative feedback from wet labs into quantitative engineering requirements.
  • Balanced user needs (tactile feel, ease of use) with strict mechanical tolerances required for the intraocular lens protection.