R&D Mechanical Engineering Co-op
Insulet Corporation, Hardware Engineering
A six-month co-op with the Hardware Engineering team, working on materials evaluation, test-fixture design, mechanical testing, and data analysis for a fluid-path component of a regulated drug-delivery device.
- Thermoformed samples and ran biomechanical testing (leak, friction, and phenolic compatibility) to assess the performance and manufacturability of 13 materials, down-selecting an alternate material for a fluid-path component.
- Designed and fabricated fixtures for test-sample preparation, manufacturing sub-assembly spec validation, insertion- and friction-force testing, and preparation of 300+ samples for chemical-compatibility testing.
- Applied statistical analysis to Instron-based insertion-force data, identifying performance drivers for 10+ single- and multi-variable design changes to a fluid-path sub-assembly.
- Performed proteomic analysis on HypoSkin (ex-vivo) tissue models exposed to continuous insulin infusion, investigating biological pathway enrichment and tissue response relative to controls.
- Used production equipment to develop in-line prototypes of modified fluid-path components.
- Supported voluntary medical-device correction and recall activities, including replacement-device fulfillment and a fixture that improved the device-teardown protocol without fume generation.
Selected work
Insulet Proprietary - Shared for Portfolio Use Only (Not for Distribution)
Instron fixture that holds a fluid-path sub-assembly at a controlled cannula offset during insertion-force testing. Swappable inserts set each offset condition, so one base fixture covers the whole test matrix.
Toggle-clamp fixture that locates a returned device under a drill press for a repeatable teardown. It replaced a hand-held method and removed fume generation from the protocol.
Benchtop process for forming nailhead terminations on fluid-path tubing. Microscope inspection of each sample tied forming parameters to head geometry and defect modes, guiding the settings used for prototype builds.
- Instron
- Fixture Design
- Biomechanical Testing
- Insertion-Force Testing
- Statistical Analysis
- Materials Evaluation



