Available for Collaboration

Joshua
Ginsberg

Mechanical & manufacturing engineer — I design hardware, build automation tools, and ship solutions that create measurable impact. Based in West Chester, PA, currently at EDLON GMM Pfaudler.

West Chester, PA · Open to Roles · UD Mech E '24
Joshua Ginsberg
Project Engineer EDLON GMM Pfaudler
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0+ yrs
3D Printing & Additive Mfg
0+
Students Mentored in DFA
$0M+
Engineering Orders Delivered
0
Safety Incidents as Lab Lead
Joshua Ginsberg

Engineer, Builder,
Problem Solver

I'm a mechanical/manufacturing engineer based in West Chester, PA — currently a Project Engineer at EDLON Fluoropolymers, where I design PTFE/PFA-lined vessels and piping, run structural FEA, and build digital tools that eliminate manual processes and accelerate production.

I graduated from the University of Delaware with a B.E. in Mechanical Engineering (Aerospace Concentration) in May 2024. My toolbox spans SolidWorks, Python automation, GD&T source inspection, composite fabrication, and full product lifecycle from concept through ECO release.

Outside the office I'm constantly building: hydroponics towers, car mods, animatronics — anything that lets me turn an idea into a physical object. I believe the best engineers are equally at home at a whiteboard and on the shop floor.

I'm working toward leading multidisciplinary teams that deliver solutions with clear, measurable impact — the kind you can point to and say "we built that."

B.E. Mechanical Engineering, UD '24 West Chester, PA SolidWorks & FEA 3D Printing & Additive Mfg Python Automation Aerospace Concentration Open to New Opportunities
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Experience

EDLON GMM Pfaudler · Avondale, PA
Project Engineer — Mechanical & Manufacturing
Jun 2024 – Present
  • Designed and released PTFE/PFA-lined vessels & piping supporting $20M+ in orders; first-article pressure/leak tests passed on first run.
  • Built parameterized FEA toolkit (SolidWorks Simulation + Python) for vacuum-support cages & billet layouts; cut mass 45% while meeting deflection/FOS; released via ECO.
  • Drove supplier quality via source inspections (GD&T, radii/edge breaks, surface finish, weld quality); incoming nonconformances down 40%, in-plant rework down 75%.
  • Digitized production tracking with SharePoint + PowerApps (standardized fields/roles, auto-revision stamps, daily exports); reduced manual entry & status-chasing, improved audit traceability.
  • Set test acceptance criteria; executed pressure, thermal-vacuum, and vibration checks; produced clear results reports; 98% on-time hardware delivery.
University of Delaware · Newark, DE
Lead Control Systems Teaching Assistant
Aug 2023 – May 2024
  • Guided ~30 students/week through control-systems lab implementation; reinforced PID, Bode, and state-space theory with hands-on MATLAB/Simulink results.
  • Hosted exam reviews for ~100 students covering common failure modes and Simulink workflows; improved section pass rates.
  • Developed and refined lab exercises, starter models, and course materials with faculty; reduced recurring student errors and improved lab completion efficiency.
University of Delaware · Newark, DE
Fabrication Lab Specialist
Aug 2022 – May 2024
  • Ran the ME Design Studio (industrial FDM/SLA printers, vacuum furnace, waterjet, laser cutter); delivered steady flow of parts for 20+ student teams and research groups.
  • Taught hands-on Design-for-Additive Manufacturing workshops to 100+ students; helped teams reach usable parts faster with fewer iterations and print failures.
  • Standardized printer material profiles and preventive maintenance schedules; maintained 98% equipment uptime, 0 safety incidents.
  • Repaired and returned key machines to service; wrote troubleshooting SOPs and machine recovery checklists that cut downtime and streamlined technician hand-offs.
Wawa, Inc. · Media, PA
Equipment Intern
May 2023 – Aug 2023
  • Analyzed HVAC/R service tickets and vendor performance to spot failure patterns and prioritize preventive maintenance.
  • Built Excel workflow for tracking assets, warranties, and SLAs; standardized evidence packs for faster warranty claims.
  • Coordinated with facilities leads and store managers to schedule replacements and minimize peak-season downtime.

Projects

A mix of professional work, personal builds, and competition engineering.

Mechanical · Personal

Tesla Model 3 Duckbill Spoiler

Parametric CAD design (Fusion 360 + Python scripting) capturing compound trunk curvature. Iterating with 3D-printed masters before carbon fiber layup from a printed/machined mold.

Fusion 360Python Carbon FiberDFM In Progress
View Details →
Mechanical · Personal

3D-Printed Hydroponics Tower

18-site recirculating aeroponic system. Submersible pump recirculates nutrient solution to a top spray manifold. Focus: printable watertight geometry, quick serviceability, food-safe materials.

SolidWorks3D Printing Fluid DynamicsIn Progress
View Details →
Engineering · Professional

Parameterized FEA Cage Toolkit

Python-scripted SolidWorks Simulation toolkit for vacuum-support cage optimization. Automated geometry sweeps cut structure mass by 45% while satisfying deflection limits and safety factors. Released via ECO at EDLON.

PythonSolidWorks Sim FEAECO
View Details →
Software · Professional

SharePoint Production Tracker

End-to-end digitization of production tracking at EDLON using SharePoint lists and PowerApps. Standardized fields, auto-revision stamps, and daily status exports eliminated manual data entry and status-chasing.

SharePointPowerApps PythonProcess Automation
View Details →
Mechanical · Personal

Sparky the Firefighter

Full restoration and modernization of a vintage animatronic Dalmatian. Mechanical rebuild, electronics overhaul, and 3D-printed replacement components for worn/missing parts.

3D PrintingElectronics Mechanical Restoration
View Details →
Aerospace · Academic

ASAE Competition Aircraft

Led engineering design as Wings Lead Engineer for a competition aircraft with integrated glider attachment mechanism. Managed structural and aerodynamic design in SolidWorks with a cross-functional student team.

SolidWorksAerodynamics Composite MaterialsTeam Lead
View Details →
View Full Project Gallery & Detailed Write-Ups

Skills

CAD & Design

SolidWorksFusion 360 AutoCADGD&T (ASME Y14.5) DFM / DFATooling Design Tolerance Analysis

Manufacturing & Fabrication

FDM / SLA 3D PrintingCarbon Fiber Layup WaterjetLaser Cutting CNC RouterVacuum Forming Composite Materials

Engineering Analysis

FEA (SolidWorks Sim)MATLAB / Simulink PID ControlState-Space FMEADesign of Experiments Bode Analysis

Digital & Automation

PythonExcel / VBA SharePointPowerApps PLM / BOMChange Control (ECO) Agile / Jira

Quality & Testing

Source InspectionAS9100 / AS9102 Pressure TestingThermal-Vacuum Testing Vibration TestingFirst Article Inspection RCA / 8D

Project Management

V&V PlanningTechnical Writing Supplier CoordinationProcess Mapping P&ID DocumentationLean / Kaizen Risk Management

Let's Work
Together

Whether you have a project in mind, a role that fits, or just want to connect — I'd love to hear from you.

Open to Full-Time & Contract Roles
Mechanical · Personal · In Progress

Tesla Model 3 Duckbill Spoiler

A fully parametric duckbill spoiler designed to fit the compound-curved trunk lid of a Tesla Model 3. The goal is a clean, factory-flush fit with an aggressive functional profile — designed from scratch, not purchased off the shelf.

Design Approach

  • Python script samples the trunk surface geometry and generates a parametric sketch in Fusion 360, ensuring the base flange matches the compound curvature exactly.
  • Multiple iterations printed in PLA/ASA to validate fit before committing to composite tooling.
  • Final mold machined from printed master + filler/primer surface prep for a clean carbon fiber layup.

Manufacturing Plan

  • Dry carbon fiber layup (2×2 twill, 3K) with vacuum bag consolidation.
  • Hardware: M6 T-nuts bonded into foam core; bolt-on fit to existing trunk lid holes.
Fusion 360Python Carbon Fiber LayupDFM Vacuum BaggingIn Progress
Mechanical · Personal · In Progress

3D-Printed Hydroponics Tower

An 18-site recirculating aeroponic grow tower built entirely from 3D-printed components. A submersible pump circulates nutrient solution from a reservoir to a top spray manifold, which mists root zones as the solution cascades down the tower.

Design Goals

  • Watertight geometry achieved through perimeter-only slicer settings and tight tolerances at interlocking joints.
  • Food-safe PETG throughout — no PLA near the nutrient solution.
  • Snap-fit pod design for single-hand plant swaps without tools.
  • Modular tower segments — add or remove height in one print.

System Details

  • 18 net-pot sites, 2-inch pots, suitable for lettuce, herbs, and small fruiting plants.
  • 500 GPH submersible pump, 15-min on / 45-min off cycle timer.
  • Reservoir: 5-gallon HDPE bucket with printed lid and fill port.
SolidWorks3D Printing (PETG) Fluid SystemsDFMIn Progress
Engineering · Professional · EDLON GMM Pfaudler

Parameterized FEA Cage Toolkit

Vacuum-jacketed vessels require external support cages to resist atmospheric pressure loading. The original cage designs were sized conservatively by hand — heavy, slow to iterate, and inconsistently documented. I built a Python-scripted SolidWorks Simulation toolkit to automate the entire optimization loop.

How It Works

  • Python drives SolidWorks via its API: parameterizes geometry (wall thickness, rib spacing, hole diameter), runs static FEA, extracts max deflection and min FOS, then logs results to a spreadsheet.
  • Automated sweep across a configurable design space — hundreds of simulation runs that would have taken weeks by hand.
  • Output: Pareto front of mass vs. deflection, with recommended design highlighted.

Results

  • 45% mass reduction on production cage design while meeting all deflection and safety factor targets.
  • Released through formal ECO process at EDLON; now used as the standard cage sizing tool.
  • Reusable for billet layouts and other vessel support geometries with minimal reconfiguration.
PythonSolidWorks Simulation FEAECO / Change ControlStructural Analysis
Software · Professional · EDLON GMM Pfaudler

SharePoint Production Tracker

Production tracking at EDLON lived in a tangle of paper travelers, email threads, and disconnected spreadsheets. Status calls were 20 minutes of "let me check" — no single source of truth. I built an end-to-end digital tracker on SharePoint + PowerApps in about three weeks.

What Was Built

  • SharePoint list schema designed around the job lifecycle: quote → design → fab → test → ship.
  • PowerApps front-end for shop floor entry — tablet-friendly, no SharePoint training required.
  • Auto-revision stamps and required-field validation prevent incomplete records from being submitted.
  • Daily summary export (Python + Power Automate) delivered to the engineering team each morning.

Impact

  • Eliminated all manual data entry and status-chasing; on-time job closures improved measurably.
  • Audit traceability: every status change timestamped and attributed to a user.
  • Adopted across the full production floor within two months of launch.
SharePointPowerApps PythonPower AutomateProcess Automation
Mechanical · Personal · Restoration Project

Sparky the Firefighter

Sparky the Firefighter

Sparky is a vintage animatronic Dalmatian owned by the Indian River Fire Company — a beloved mascot that had been silent for years. I took on the full restoration as a personal project during my senior year at the University of Delaware.

Mechanical Work

  • Disassembled the entire drive and actuator system; replaced worn gears, cables, and motor mounts.
  • 3D-printed replacement structural brackets and linkage parts that were no longer available.
  • Rebuilt the differential drive system for reliable straight-line and turning motion.

Electronics Overhaul

  • Replaced the original 75 MHz transmission system with a modern 2.4 GHz system for range and reliability.
  • Diagnosed and replaced the central electronic controller — the original was damaged beyond repair.
  • Rewired the audio system and integrated a new speaker amp for the siren and voice lines.
3D PrintingElectronics Mechanical RestorationRC SystemsAnimatronics
Aerospace · Academic · SAE Aero Design East

ASAE Competition Aircraft

SAE International Aero Design East — Advanced Class. The mission simulates wildfire combat: a Primary Aircraft (PA) drops a Powered Autonomous Delivery Aircraft (PADA), which deploys a Ground Transport Vehicle (GTV) to a target. I served as Wings Lead Engineer.

My Role

  • Designed and analyzed the wing and tail assembly for the Primary Aircraft: lift requirements, control surface sizing, structural spar layout.
  • Led composite fabrication of the wing panels (fiberglass skin over foam core); coordinated layup schedule with a team of 6.
  • Integrated the PADA release mechanism into the fuselage — mechanical latch triggered by servo command at altitude.

Technical Details

  • PA carries a 4 lb water payload + PADA; total gross weight ~14 lbs.
  • Wing: high-lift airfoil, 72-inch span, tapered planform.
  • PADA: autonomous navigation to GPS and color targets using Pixhawk flight controller.
  • GTV: manually controlled RC vehicle assembled post-drop, carries 2 lb water payload.
SolidWorksComposite Fabrication AerodynamicsPixhawk / Autonomous SystemsTeam Lead