Portfolio

Experience & portfolio.

A structured look at my work across enterprise product development, client engagements, patented inventions and the builds I make in my own lab.

01 · W-2 Roles

Career milestones

Eight years of connected hardware at Allegion, plus internships at Tesla, NASA Marshall and SonaCare.

Keypad smart deadbolt, exterior keypad and interior thumbturn assembly

WiFi Smart-Lock Product Family

System Engineer III → Senior System Engineer · Allegion · 2018–present

The build

I own the system for a family of WiFi deadbolts and lever locks, from concept to retail launch: I write the PRDs, SRDs, FRDs and ADRs that seven subsystem teams build against, maintain the ICDs between them, and coordinate those teams as a team of teams. I run the DFMEAs, SFMEAs, risk register and FRACAS process, present System Design Reviews to directors, and mentor two engineers day to day.

Requirements (PRD/FRD/SRD/ADR)
System Architecture & ICDs
DFMEA / SFMEA
FRACAS & Root Cause Analysis
Integration Test
Teams of Teams
Director-Level Reviews

Tesla Model X with its falcon-wing doors open

Model S / X Body & Fastener Systems

Body System Engineering Intern · Tesla · 2014–2015

The build

Two internships. I released GD&T CAD models for cast and stamped aluminum structural parts on Model S and X, and selected and validated fasteners with torque-to-failure, tensile and clamp-load testing, documenting the root cause of every failure.

SolidWorks CAD
GD&T
Fastener Testing
Structural Design
Root Cause Analysis

RS-25 PID Heat Map Tool

Propulsion Systems Analysis Intern · Liquid Engine Systems Branch (ER21) · NASA Marshall · 2017

The build

Every RS-25 hot-fire test produces data from about 6,000 sensors that has to be assessed within seven days. On a five-intern team supporting the Space Launch System’s main engine, I built the PID Heat Map Tool, a MATLAB and Python tool with a full GUI that maps which sensor parameters the assessment plots use, how often and in which plots, so engineers can see coverage gaps and redundant analysis. Our team also wrote a script template and a worked LOX-system example so the next engineers know why each plot exists and how to read it.

MATLAB
Python
GUI Development
Data Assessment
Systems Engineering
Technical Documentation

Sonablate HIFU system, with the treatment probe mounted on its articulating arm

Sonablate HIFU Probe

Product R&D Engineering Co-Op · SonaCare Medical · 2016–2018

The build

I worked on the Sonablate probe, which delivers precise, focused ablative energy into the prostate. The probe housing and the entire assembly were within my design scope, including its demanding medical sealing. I took the design from concept through SolidWorks models, 3D-printed and cast urethane prototypes, fabrication, validation testing and the test reports, and I set the cable specifications and drew the 2D/3D electrical routing.

Medical Devices
Housing & Assembly Design
Medical Sealing
SolidWorks CAD
Cast Urethane
Testing & Validation

Also at Allegion

Systems Engineering Intern Program

Allegion · 2026

I ran Allegion’s systems engineering intern program end to end: I found candidates, reviewed résumés, scheduled the interviews, and owned the final call on who got hired.

Candidate Sourcing
Interview Coordination
Hiring Decisions

Independent Reviewer Agent

Allegion · Azure DevOps

I’ve built an agent that performs independent reviews at system design review gates: it reads the work items and documents in Azure DevOps and writes up findings, thoroughly and cheaply.

AI Agent Development
Azure DevOps
Design Reviews

ML Models & Data Pipelines

Allegion · Data Scientist Cohort · 2019–2020

Alongside my systems role I joined Allegion’s data scientist cohort, where I built machine learning models and automated data pipelines that fed product and engineering strategy decisions.

Data Analysis & ML
Python

02 · Consulting

Client engagements

Paid client outcomes through The Dimensional Forge. Every one was quoted before work started; open any of them to see the accepted proposal.

$2,250Investment

150hHours

0–2·4Forge Phases

Stealth Wallet

Design through production · The Dimensional Forge · 2025

The build

I took a client’s wallet from sketch to production readiness: CAD, photorealistic renders, proof-of-concept prototypes, DFM/DFA, supplier quotes, tooling, a pilot run and launch prep.

SolidWorks CAD
Rendering
DFM / DFA
Supplier Quoting
Tooling & Pilot Run

~$9.4KInvestment

235hHours

0–4Forge Phases

Electromechanical Product with iOS Integration

Full-cycle development · The Dimensional Forge · 2025

The build

Full-cycle development for one client: multi-discipline architecture, 3D CAD, patent drawings, two prototype builds (a proof of concept, then a refined build in a printed enclosure), an iOS app MVP talking to the hardware, and production prep.

System Architecture & ICDs
Electromechanical Integration
Patent Drawings
iOS Integration
DFM

$1,518Investment

38hHours

0–2Forge Phases

Tactical Light Prototype

Mechanical + electrical prototyping · The Dimensional Forge · 2025

The build

I took a tactical light from requirements and ideation through full CAD, mechanical and electrical architecture, a physical build and testing, and shipped a working proof of concept.

Electrical Architecture
Electromechanical Integration
Rapid Prototyping
Li-ion Power
Soldering

More client work

Automated Machine MVP

Client build · 2026

From the client’s reference CAD I built a working MVP with actuated panels, sequenced motion and button controls, and verified every mechanism.

Mechanism Design
3D Printing
V&V

Medical Device Reverse Engineering

Client teardown · 2026

A measured, photographed teardown of a client-supplied device, parametric SolidWorks models of the key parts, and native CAD, STEP files and drawings.

Reverse Engineering
SolidWorks CAD
Engineering Drawings

Forty Drawings, One Title Block

Client drawing package · 2026

Updated the title block and branding across 40 SolidWorks drawings, using a VBA macro for the repetitive changes.

Engineering Drawings
VBA Automation

Custom Pokéstop LED Sign

Client build · 2026

Acrylic cut to the silhouette, an LED neon flex front face and a spinnable pole mount, run for more than 8 hours straight before delivery.

LED Neon Flex
Acrylic Fabrication
Runtime Testing

Battle Bot Engineering Tutoring

Client tutoring · 4 sessions · 2026

Four hands-on sessions with a ten-year-old: build a new battle bot from a kit and diagnose a broken one. He did all the hands-on work; I asked questions.

Technical Mentorship
Troubleshooting

Product Strategy Session

Client consultation · 2025

One live session on a client’s product goals, manufacturing approach and priorities, with the recording and a written summary of next steps.

Product Roadmapping
Manufacturing Strategy

03 · Patents & Credentials

Patents & Credentials

Three inventions, from proving who opened a lock to helping a person stand up, and the training behind them.

US 11,962,594 · Issued Apr 16, 2024 · Co-inventor

Blockchain for Access Control (System Architecture)

What it covers

Secured foundational claims for the physical hardware infrastructure, linking smart electronic locking mechanisms with decentralized node validation networks.

Access Control
Distributed Ledger
Invention & Patents

US 12,609,936 · Issued Apr 21, 2026 · Co-inventor

Blockchain for Access Control (Protocol & Method)

What it covers

Secured process claims for the software sequence, token-minting mechanics, and cryptographic verification loops running across mobile endpoints and distributed ledgers.

Access Control
Distributed Ledger
Mobile Credentials

US2019/032088 · Issued Aug 24, 2019

Adjustable Passive Standing Assistance Device

What it covers

An adjustable assistive device that helps a person stand using passive mechanics rather than powered actuation.

Mechanism Design
Assistive Devices
Invention & Patents

Education & Credentials

Claude Academy course completion badge: Claude 101, presented to Sean Neal

Anthropic · Issued Oct 2026

Claude Academy: Claude 101

Credential ID 39ba9e5bc8ee193bd513f881dbd75f51

Verify credential ↗

Claude Academy course completion badge: AI Fluency: Framework and Foundations, presented to Sean Neal

Anthropic · Issued Oct 2026

Claude Academy: AI Fluency: Framework & Foundations

Credential ID 2dbbf7f810bc69016f8668cbc5969fc2

Verify credential ↗

04 · CAD

CAD gallery

Models I designed in SolidWorks, from my own products to client work. Select one to explore it in 3D.

Drag to rotate

Bikepacking · front rack

The Roll

A 3D-printable front rack for a bikepacking roll bag. It mounts with two through straps, zip ties, or M5 bolts for a permanent install, and holds gear steady on any terrain.

05 · Independent R&D

The Forge Lab

What I build on my own time: agents, embedded hardware, local AI and a motorcycle.

VENN Everywhere

Modular agent platform · The Forge Lab

The build

An agent platform with fourteen bridges into the places work happens: chat, SMS, Telegram, calendars, files and my lab’s inference nodes. It helps me run the Forge, answering questions and 3D-print quotes over Telegram and here, as the chat widget in the nav.

AI Agent Development
Agentic Workflow Design
LLM Integration

More about VENN →

Crypto-and-QR Vending Dispenser

Embedded hardware build · in progress

The build

A gumball machine that takes on-chain Bitcoin or a Stripe payment link. A T-Display ESP32 shows the QR code and status, watches for payment, then steps a 28BYJ-48 through a ULN2003 to turn the dispense gear one full revolution. The schematic is the real wiring; I’m building it in the open.

ESP32
PlatformIO
Stepper Drivers
Payment Integration
Soldering

0cloud callsRuns on a local model

Local-LLM Obsidian Workflows

Ollama inside a vault · The Forge Lab

The build

Skills and a multi-step workflow inside Obsidian that turn a session transcript into a structured note package on a local model, built for a practitioner whose notes can’t go to a cloud service.

Obsidian
Ollama
Agentic Workflow Design
LLM Integration

650ccsingle cylinderCyberpunk cafe-bobber

Suzuki Savage LS650 Cafe-Bobber

Personal build · The Forge Lab

The build

My own motorcycle, a Suzuki Savage LS650 reworked into a cyberpunk cafe-bobber.

Fabrication

More from the lab

Watchy Firmware & Android Companion

ESP32-S3 e-paper watch · in progress

Custom firmware with a survival-game “life meters” face and calendar reminders, plus an Android app that syncs over BLE, flashes firmware and switches faces.

ESP32
Firmware
Android
BLE

Earwig

Offline meeting transcriber

A portable app I run from a USB drive that records meetings and writes speaker-labeled Markdown transcripts on the laptop. Nothing leaves the machine.

Speech-to-text
Local Models
Privacy by Design

Homelab Inference Stack

Owned hardware

An RTX 3060 node running Ollama with Qwen3 for tool calling, a Raspberry Pi 5 running memory-consolidation jobs, and a two-tier memory design.

Ollama
Qwen3
Raspberry Pi

Automated Pet Potty Sensor

Potty Spot · in development

A sensor device for pet potty training whose firmware is built as a state machine, so its behavior is defined as states and transitions before it is coded.

State Machines
Firmware
Sensors

Home Assistant Dashboard

Home automation

One dashboard for my house, media server and lab, with up/down status badges so I know a server is down before anyone asks.

Home Assistant
Dashboards

Text-to-Speech MCP Server

Developer tooling

A Model Context Protocol server that connects an AI coding agent to a local Node.js speech endpoint, so long-running tasks can announce when they finish.

Node.js
MCP
LLM & Agent Tooling

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