Alex Klein
explorer | creator | engineer
explorer | creator | engineer
Engineering Experience
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Ball Aerospace
Materials & Process Engineer Boulder, CO | February 2023 - Present |
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Space Telescope Science Institute
Design Engineer Baltimore, MD | August 2021 - December 2022
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Hopkins Baja SAE Racing
Controls Team Lead & Testing Lead Baltimore, MD | 2018 - 2022
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Ball Aerospace
Materials & Process and Manufacturing Intern Boulder, CO | Summer 2021
Facilities Engineering Intern Boulder, CO | Summer 2020 & Summer 2021
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University of Minnesota Genomics Center
Design Engineer and Development Team Remote | 2020 - 2021
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Laboratory for Computational Sensing and Robotics
Machine Shop Manager Baltimore, MD | 2019 - Present
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FreshAir Sensor LLC
Product Development Team Intern Lebanon, NH | Summer 2019 & Spring 2020
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Fidelity Management and Research Company
Intern on the Software Development Team Boston, MA | Summer 2017
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Education
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Johns Hopkins University
Baltimore, MD | Class of 2022 BS & MS in Mechanical Engineering GPA: 3.71 | Graduated with Honors Aerospace Concentration & Space Science Minor Coursework: Spacecraft Hardware Design, Space Systems Engineering, Mechanical Properties of Materials, Creo, Aerospace Structures, Rocket Propulsion, Image Processing, ArcGIS, Sustainable Development, Disaster Risk Mitigation Extracurriculars: Outdoor Pursuits Rock Climbing Instructor, SEDS Vice President, AEPi Treasurer & House Manager, LCSR Machine Shop Manager, Model UN Committee Chair |
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The Rivers School
Weston, MA | Class of 2018 GPA: 3.97 | High Honor Roll Cum Laude Society Interdisciplinary Studies Prize, Photography Prize Extracurriculars: Model UN President, Junior Class Co-President, Yearbook Editor, Newspaper Photographer, JV Soccer Captain |
Exploration
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Design Portfolio
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ASSIST Telescope Prototypes and Design Selection
for Space Telescope Science Institute, 2022 Continuing the work of my senior design project, I joined STScI and led the effort to design the ASSIST primary mirror: a segmented and electromagnetically-controlled telescope for integration into HiCAT, a chronograph testbed. After conducting a full system review of our design and assembly confidence, we identified two key high-fidelity prototypes: a 19-segment 3DOF coarse telescope primarily to test the bonding and alignment procedure, and a 7-segment 6DOF coarse + 3DOF fine telescope to test segment assembly and packing. I fully designed and sourced both prototypes while managing the project’s IRAD budget. Once assembled, we spent countless hours thoroughly testing and aligning the telescopes to gather all required data and finalize the design path. Combined with optical modeling, we finalized COTS components and I completed the ASSIST mirror design: 19-segment OAP 3DOF coarse + 3DOF fine, utilizing all the knowledge we had gained in the process. We made a quick 3-segment prototype of the final design and reached 11nm RMS with coarse actuation only, and incredible fine actuation control with custom electronics. I helped create the budget and write a NASA proposal for the hardware to be created and tested in 2024 to 2026 (pending review and funding). |
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6DOF Hexagonal Telescope Segments
for Space Telescope Science Institute, 2022 For the JHU MechE senior design capstone project, my team needed to create a compact mechanism for controlling telescope mirrors for the Makidon Lab at STScI. Each segment must be moved in all 6 degrees of freedom, control to nanometer-level precision, and be cleanroom compatible. After iterating through numerous designs (including full prototypes with custom differential actuators and flexures) we created a mechanically driven coarse stage and a piezoelectric fine stage, both in modified Stewart platforms configurations. After verifying assembly procedures, we aligned a 3-segment telescope to 37nm RMS wavefront error, giving confidence in the overall design concept. We measured the ranges and resolutions for the actuator to provide valuable specifications for the next level of prototyping (next design project). The work was submitted to successfully receive an IRAD grant for future development. View the summary slides. |
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Testing Program Infrastructure
for Blue Jay Racing, 2021
While not technically a physical “design project”, my work as Testing lead on Hopkin’s Baja SAE team was critical in closing the loop on the engineering design cycle for the off-roading car. We had not properly tested individual components or major vehicle systems in years prior, so I took the initiative to establish a testing infrastructure. Modeled off of industry practices, I created guidelines and standards to properly design, review, and execute tests, and then to analyze and correlate the results once the test is completed. These included templates with prompts for testing plans, test readiness reviews, and test completion reviews. With my knowledges of the car and by discussing with design team leads, I brainstormed and described all 100+ tests that could be performed during the design cycle (from load determination, to proof tests, to drive characteristics, etc) and categorized them. With various weighting measures, I prioritized each test for the 2021-22 season, and then managed the execution of the top ~20 tests and the implementation of their results. This not only led to greater performance of the team’s end product, but also set the team for success in future years and helped to achieve a 1st place design finish at competition (never done before in the teams 18 year history). View the summary slides by clicking here.
for Blue Jay Racing, 2021
While not technically a physical “design project”, my work as Testing lead on Hopkin’s Baja SAE team was critical in closing the loop on the engineering design cycle for the off-roading car. We had not properly tested individual components or major vehicle systems in years prior, so I took the initiative to establish a testing infrastructure. Modeled off of industry practices, I created guidelines and standards to properly design, review, and execute tests, and then to analyze and correlate the results once the test is completed. These included templates with prompts for testing plans, test readiness reviews, and test completion reviews. With my knowledges of the car and by discussing with design team leads, I brainstormed and described all 100+ tests that could be performed during the design cycle (from load determination, to proof tests, to drive characteristics, etc) and categorized them. With various weighting measures, I prioritized each test for the 2021-22 season, and then managed the execution of the top ~20 tests and the implementation of their results. This not only led to greater performance of the team’s end product, but also set the team for success in future years and helped to achieve a 1st place design finish at competition (never done before in the teams 18 year history). View the summary slides by clicking here.
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96 Channel Pipette Matrix Spacer
for University of Minnesota Genomics Lab, 2021 Transferring samples from vials in a rack into a well plate is a tedious process for users at the University of Minnesota's Genomics Lab. On a team to automate the entire process, I worked on the channel matrix, which changes the grid spacing of the pipette tips. After three full iterations, the final design utilizes two 1/8" stainless rods in both lateral and longitudinal directions to support 96 resin 3D printed carriages. Pipette tips attach below the carriages and tubing is connected on top to syringes for pressure build up. The rods are supported on both ends by bearing carriages, which ride on square aluminum rails and are spaced by their width (closed configuration) and by limiting straps (open configuration). The device is customizable for the lab users based on the spacing of rack and well plate that is being converted, and each of the approximately 400 individual pieces can be easily serviced or replaced. |
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Steering Rack and Pinion
for Blue Jay Racing 17XT, 2020 The steering rack and pinion converts the driver's torque on the steering wheel to linear force onto the tie rods to steer Blue Jay Racing's vehicle. After reviewing the past 5 years of the team's rack design, I determined the major previous design failures and recalculated the steering system's loading conditions from experimental strain gauge data. Major changes from previous years include the support tube to eliminate sleeve bearing alignment, 33% weight reduction due to the new bimetallic rack, and an ergonomic 210 degrees lock-to-lock steering angle. Designed and analyzed in Solidworks for desired FOS 2.0 and expected 50-60 hour lifetime. |
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COVID Testing Vial Uncapping Machine
for University of Minnesota Genomics Lab, 2020 During the Fall 2020 college semester, the University of Minnesota tested each student and on-campus affiliate for COVID-19 on a daily basis, which resulted in approximately 1.5 million tests per month. To automate the process of uncapping the received vials, we created a machine to fit under a fume hood and process 96 samples at a time. I designed and tested numerous 3D printed gripper designs to slide down over the caps, latch underneath a lip, pull the cap off the vial, and dispose of the contaminated object through flexible tubes and down a main chute. Towards the end of the entire fabrication process, the Genomics Lab needed to switch to screw top vials, so I brainstormed an alternating lead screw to unscrew 12 caps at once. After creating a full prototype, I optimzed the final version to reduce friction and be fully sealed from any airborne contaminates. |
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Brake System
for Blue Jay Racing 16XT, 2020 As Controls lead of Hopkins Baja, I designed the entire brake system, which includes the pedals, bias bar, master cylinders, brake line, calipers, and rotors. Following the goals of the overall vehicle, some components are off-the-shelf for easier manufacturing and serviceability. I utilized Solidworks to design some components, perform FEAs, and package the parts into the larger car assembly. Click here to view my presentation on the system. |
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Automated Sensor Resistance Tester
for FreshAir Sensor, 2019 FreshAir Sensor makes patented devices to detect tobacco and marijuana smoke in hotels and apartments. After printing the chemical solution on each plate, the resistance must be tested on all of the manufactured sensors. The device pictured clamps down onto the plate of sensors and contacts them with spring pins. PCB board (which I did not make) connects to an online portal and indicates which sensors are outside of the desired threshold. The device automates the process of testing each sensor with a multi meter to reduce manufacturing and production time. |
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Featured Projects
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goBuddy
My partner, Max, and I brainstormed a novel mobile application to coordinate travel plans with friends and created a proof of concept on the Apple App Store. Here’s the description: goBuddy is an app to post your trip plans and ideas for your close friends to see. You can browse the feed or sort postings by type, duration, dates, and location to note those of interest. Whether planning a summer of backpacking abroad, exploring a city for the weekend, or going to a baseball game after work, goBuddy eliminates the hassle of flooding text chats or Facebook groups with plans. Choose the outings that are compatible with your schedule and interests, grab your Buddy, and Go! After gaining some traction and gaining valuable user feedback, we incorporated the company, brought on more talent, and have begun developing a fully-fledged app. As the Cheif Operating Officer, I focus on business operations, marketing, seeking investment, and platform monetization. Stay tuned for the next release |
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Toward a Cohesive Space Strategy: Goal Alignment Recommendations with Lessons from the James Webb Space Telescope
My final paper for the Politics of Outer Space course focuses on the flow down of goals from high-lever NASA strategies to specific engineering requirements, and what can be improved throughout the process. I conclude with a broader approach to the organization’s role in future US space missions. View the paper by clicking here.
My final paper for the Politics of Outer Space course focuses on the flow down of goals from high-lever NASA strategies to specific engineering requirements, and what can be improved throughout the process. I conclude with a broader approach to the organization’s role in future US space missions. View the paper by clicking here.
Topographical US Map
3D printed PLA pieces assembled onto 24" x 36" sheet metal backing.
3D printed PLA pieces assembled onto 24" x 36" sheet metal backing.
Blue Jaw Racing Cost Reduction Report
A new addition to the 2020 competition, BAJA SAE tasked teams to come up with ways to reduce their costs (both operationally and according to their internal cost auditing system). I led a team of 5 students to brainstorm and quantify cost savings on the car. View the report by clicking here.
A new addition to the 2020 competition, BAJA SAE tasked teams to come up with ways to reduce their costs (both operationally and according to their internal cost auditing system). I led a team of 5 students to brainstorm and quantify cost savings on the car. View the report by clicking here.
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Flying Ring Optimization
We focused on the steadiness of a flying ring in order to maximize the distance it will travel. After researching the governing aerodynamic properties and relationships, we created equations of motions for the flight. Our MATLAB model incorporates the initial and iterated angle of attack of the disk into the distance calculation. We optimized for distance by varying radius and mass of the disk, averaging many throws across initial angle-of-attack angular position and velocity. |
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Hedonic Price Model of New England Ski Areas
Using a database of 60 New England ski areas, the correlation between several primary resort characteristics and the 2018-2019 adult day ticket prices is analyzed. A hedonic price model is used to run an OLS regression on the data and determine the importance and significance of 13 variables. This study determines that ski area size (including number of trails, skiable acres, and vertical drop), the snowmaking capabilities of the mountain, the number of nearby restaurants, and the proximity of a ski area to local residents and population centers have the greatest positive influence on ticket price. The hedonic model is also used to form a ranked list of ski areas in New England by their expected ticket price, representing resort quality, and how this compares to their actual ticket price, representing resort value. This study can provide valuable information to ski area management and tourism offices across New England, who can better understand the motivations for alpine skiing customers in the region. Click here to view the paper.
Using a database of 60 New England ski areas, the correlation between several primary resort characteristics and the 2018-2019 adult day ticket prices is analyzed. A hedonic price model is used to run an OLS regression on the data and determine the importance and significance of 13 variables. This study determines that ski area size (including number of trails, skiable acres, and vertical drop), the snowmaking capabilities of the mountain, the number of nearby restaurants, and the proximity of a ski area to local residents and population centers have the greatest positive influence on ticket price. The hedonic model is also used to form a ranked list of ski areas in New England by their expected ticket price, representing resort quality, and how this compares to their actual ticket price, representing resort value. This study can provide valuable information to ski area management and tourism offices across New England, who can better understand the motivations for alpine skiing customers in the region. Click here to view the paper.
Trump Twitter Discourse
Donald Trump, the Republican Candidate in the 2016 United States Presidential election, used Twitter to insult and troll his opponents, particularly Democrat Hillary Clinton. By looking at 230 @realDonaldTrump Tweets which address Clinton during the campaign, this study analyzes Trump’s statements sociolinguistically and statistically, comparing the tweets’ structure and rhetoric between two time periods. Once Clinton became his primary opponent, Trump’s tweets became slightly more multimodal, the number of tweets addressing Clinton decreased, and the average length of these tweets also decreased. However, there was no significant change in Trump’s rhetoric toward Clinton. Further analysis reveals that Trump’s shorter tweets gained more popularity, as well as statements referencing Clinton’s email scandal. These comparisons and linguistic analyses of Trump’s statements provide insight into his communication process and campaign strategy during the election. Click here to view the paper.
Donald Trump, the Republican Candidate in the 2016 United States Presidential election, used Twitter to insult and troll his opponents, particularly Democrat Hillary Clinton. By looking at 230 @realDonaldTrump Tweets which address Clinton during the campaign, this study analyzes Trump’s statements sociolinguistically and statistically, comparing the tweets’ structure and rhetoric between two time periods. Once Clinton became his primary opponent, Trump’s tweets became slightly more multimodal, the number of tweets addressing Clinton decreased, and the average length of these tweets also decreased. However, there was no significant change in Trump’s rhetoric toward Clinton. Further analysis reveals that Trump’s shorter tweets gained more popularity, as well as statements referencing Clinton’s email scandal. These comparisons and linguistic analyses of Trump’s statements provide insight into his communication process and campaign strategy during the election. Click here to view the paper.
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Backyard Projects
in Vermont 8ft x 10ft Cabin, 2016 (with father) 8ft x 8ft Treehouse, 2017 Dam, Waterwheel, & Wooden Gearbox, 2018 |
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Cartography
from Geospatial Information System (ArcGIS) class
from Geospatial Information System (ArcGIS) class
Even more things...
Wing-Box Structure design optimization, analysis, build, test of the component
Wind Energy Integration and Storage with the Rail Tie Wind Project in Wyoming as a case study
Beam Stress and Displacement Analysis for any material and shape to calculate the maximum stress due to any forces or moments
Aerospace Fastening: Bolts & Rivets, Welding, and Adhesives for various design scenarios and load cases
Material Design for Acoustic Loads of Spacecraft during Launch: acoustic and fatigue loading
Executive Directorate of Boeing: Background guide for the JHUMUNC committee on the 737 MAX crashes
Committee on the Peaceful Uses of Outer Space: Background guide for the JHUMUNC committee on space commercialization
Twisted Ribbon Geometry and Design of the Antioch Mosaics, a meandering flat ribbon waving across in a repeated manner
Telescope Mirror and Deep Submersible presentations for Materials Selection course
HIV Response to Immune Therapy for MATLAB Class Project to model the spread of a virus with non-linear ODEs
SolSat: Introduction to Space Science and Technology CubeSat group final project
PIVOT: Engineering for Sustainable Development energy saving technology proposal group project, 2019
Calculus: A: Table of Contents & Pre-Calculus, B: Derivatives, C: Integrals, D: Series, E: Multivariable Calculus
Biology and Chemistry - Elements, Molecules, Genetics, Reactions, Biotic Systems, Ecology, Moles, and Equilibrium
Linear Algebra - Transformations, Subspaces, Coordinate Systems, Determinants, Diagonalization, and Applications
Differential Equations - Solving and Analyzing 1st, 2nd, and Nth order ODE, Systems of ODE, Non-Linear Functions
Wing-Box Structure design optimization, analysis, build, test of the component
Wind Energy Integration and Storage with the Rail Tie Wind Project in Wyoming as a case study
Beam Stress and Displacement Analysis for any material and shape to calculate the maximum stress due to any forces or moments
Aerospace Fastening: Bolts & Rivets, Welding, and Adhesives for various design scenarios and load cases
Material Design for Acoustic Loads of Spacecraft during Launch: acoustic and fatigue loading
Executive Directorate of Boeing: Background guide for the JHUMUNC committee on the 737 MAX crashes
Committee on the Peaceful Uses of Outer Space: Background guide for the JHUMUNC committee on space commercialization
Twisted Ribbon Geometry and Design of the Antioch Mosaics, a meandering flat ribbon waving across in a repeated manner
Telescope Mirror and Deep Submersible presentations for Materials Selection course
HIV Response to Immune Therapy for MATLAB Class Project to model the spread of a virus with non-linear ODEs
SolSat: Introduction to Space Science and Technology CubeSat group final project
PIVOT: Engineering for Sustainable Development energy saving technology proposal group project, 2019
Calculus: A: Table of Contents & Pre-Calculus, B: Derivatives, C: Integrals, D: Series, E: Multivariable Calculus
Biology and Chemistry - Elements, Molecules, Genetics, Reactions, Biotic Systems, Ecology, Moles, and Equilibrium
Linear Algebra - Transformations, Subspaces, Coordinate Systems, Determinants, Diagonalization, and Applications
Differential Equations - Solving and Analyzing 1st, 2nd, and Nth order ODE, Systems of ODE, Non-Linear Functions
Photography
Ever since I was 5, I have always been intrigued by a camera. Always striving for that perfect shot to tell the story in front of the lens. I have found that photography has abilities that humans lack; being able to slow down time or completely freeze it cannot solely be done with human eyes.
Experience Includes:
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Brand Management and Marketing:
AK Online Solutions, Founder: Web Design, Online Advertisement, Search Engine Optimization, Social Media Management, Logo and Brand Design.
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LiveDry Apparel, Director of Marketing: Managed and created content for the company website and Instagram. Created successful Kickstarter crowdfunding campaign which raised 174% of goal.
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FlashGear Footwear, LLC, Creative Director: Provided brand with on-demand lifestyle photos and graphic design for promotional use.
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Contact Me
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