Henri Stephan:
Portfolio
I am a creative and passionate engineer who loves analyzing problems and creating innovative solutions. Below you will find my passion projects and professional experience.
Contact Me:
415-999-1776
Engineering Experience
Mechanical Engineer Intern:
ZIP Launchpad Rapid Prototyping Lab
Aug 2022 - Aug 2023
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Helped startups go from an idea to a functional prototype of their desired product.
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Used CAD design, 3D printing, laser cutting, woodworking, Adobe Suite, CNC routers, and various other hand tools and machines.
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Researched new manufacturing methods and created standard operating procedure for resin casting.
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Collaborated with electrical Engineers and graphic designers.
Adjustable Bike Frame - Allows for sizing adjustment for growing kids. One design uses fixed adjustments while the other uses a clamp for fine adjustment.
Webcam Phone Mount - Allows for the use of a smartphone as a webcam or second screen for high quality video, calls, or as a productivity aid.
Automatic household planter - Measures ambient light, temp, humidity, water level, and soil moisture. Automatically waters plant and provides light as needed.
Design and Manufacturing Lead: Aztec Racing Regenerative Brakes
Aug 2022 - May 2023
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Senior design project, collaborated on a six person team to develop the regenerative braking system and a test bench to establish the functionality and efficiency of the system.
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Performed CAD design, structural analysis, and mathematical modeling.
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Organized manufacturing process and performed tasks such as TIG welding, water jetting, and the use of hand and CNC lathes.
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Final product was a test bench with a full electric drivetrain and functional regenerative brakes.
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Link to project portfolio
Personal Projects
Topographically Optimized Drone Frame
This project was a collaboration with Ben Gaviola as a way to refine our competencies in the optimization of components. This drone frame was designed using 100 Newton load cases. The cases were for rough landings, side impacts, and inverted landings (top impact). The result had a 60% reduction in mass while maintaining strength and rigidity.
BMW E30 Restomod
1987 BMW 325ES with an engine conversion from a 1998 BMW 328 (M52b28). A BOM was maintained through the project, and wiring diagrams and part drawings were used to determine compatibility between OEM parts and wiring. This project was completed using OEM BMW components with basic hand tools, the total cost of the engine conversion was under $1500. Further upgrades include a 3.73 final drive limited-slip differential, coilover suspension, and a Z3 steering rack. Car has been my daily driver since completion of the modifications (over 30,000 miles without issue).
Flat Packing Lounge Chair
This project was an attempt to design furniture which is both aesthetically pleasing and inexpensive. This design is easily assembled and disassembled without fasteners, packs flat, and can be cut out from a variety of materials using a router. The cardboard prototype supported over 300 pounds without visible deflection or damage.
Electronically Assisted Programmable Workout Device
A finger strengthening tool for rock climbers with pre-programmed guided workouts. Timed light sequences are used to guide hand placement, number of sets, and the length of each set. Additional workouts can easily be added in and then selected by the user through the press of a button. I created the prototype circuit with an Arduino, wrote the code for the system, and designed the device itself in Solidworks.