Thomas Alkhoury

About Me

Portfolio

Rocket Nose Cone Development

Along with 2 other engineers of uORocketry, research and testing went into designing a nose cone, its mould, as well as selecting its materials and manufacturing process. This nose cone is for a rocket which has an apogee of 30,000 feet, travelling at Mach 2.5 and will be competing against other university teams. Initial CAD design, excluding the nose cone tip and bracket was done by myself using SolidWorks. CFD and consulting was done by all team members.

Automated Wrapping Machine

Along with 4 other students, a machine designed to automate the process of wrapping boxes with gift wrap was designed and modeled using CAD. The cutting mechanism was designed entirely by myself, and was designed using a hydraulic cylinder in order to minimize blade replacement.

Environmental Regulator

Designed especially for the consequences of COVID, the environmental regulator is an Arduino-based system which has a temperature, humidity, AQI (air-quality index) sensor. According to the current season and target temperature, this system will open the window to change the temperature and humidity, improve the AQI, and reduce the amount of carbon emissions of a room.

Lateral Offset Geartrain Design

Along with 3 other students, a lateral offset geartrain had to be designed from the ground up, selecting certain parts (mainly the gears) from catalogues. Geartrain kinematics, tolerances, forces, drawings, component selection, component design, lubrication, FEA, as well as an engineering report all had to be done from scratch by the team.

Design

Car Speaker Enclosure Designs

Worked on developing, designing, CAD and testing of custom car speakers for a specific model of speakers and sold 3D printed products to customers. Designed to withstand fatigue loads as well as high temperatures.

3D Printed Leak-Proof Portable Cigar Humidor

Worked on prototyping, developing, designing, CAD and testing of a 3D Printed, print-in-place portable cigar humidor, which uses commercial weather strips as well as a Boveda pack in order to regulate the humidity. Box is designed to be print-in-place to ensure low post-processing time as well as efficient mass production of box. 3D Printed prototype as well as STL file was sold to client.

Model Rocket

Worked on model rocket assembly design, CAD, aerodynamic stability testing using software. It is functional and designed to use a model rocket engine in order to reach roughly 100m altitude. Each part was then 3D
printed, assembled and the model was tested.

SolidWorks Can Opener

CAD model of a can opener modeled using SolidWorks. The dimensions were taken off a real can opener, model was done for a 1st year Mechanical Engineering class CAD project.

Experience

TA Designs (Self-Employed) – Mechanical Designer                               January 2021 - Present
Consulting with various customers/parties in order to model, design and simulate their ideas, prototypes and designs (ex: Designed a sealed 3D Printed humidity box)
uORocketry – Airframe Engineer/Nose Cone Project Lead                   January 2020 - Present
Designed and tested rocket nose cone using CAD and CFD for Spaceport America Cup
Design, CAD and simulation of various parts and assemblies for airframe, propulsion, and avionics sub-teams such as rocket fins mount and hot fire test stand
American Society of Mechanical Engineers (ASME)                                       April 2021 – Present
Better Building Materials – Window Technician                                       July 2017 - August 2019
Tested window frames to meet building code using Smart-Lab technology

Skills
Java, C/C++, Python
Mechanical CAD
3D Printing
Arduino
Using Lab Equipment
Raspberry Pi
MATLAB
English, French, elementary Chinese
Word, Excel, Powerpoint
MIG Welding
Soldering
Quartus II (FPGA)
Electrical Circuits
CAD/Stress Simulation
SolidWorks
AutoCAD
Fusion 360
LBNL THERM (Heat Transfer)

Contact

• Instagram
• GitHub

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