Engineering Portfolio

Ava Keras

Welcome to my website! I'm a Mechanical Engineering student at the University of Waterloo. Currently, I am in Tesla's Cybercab team working as a manufacturing design engineer. Come see what I've been up to!

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Disclosure notice

Due to strict non-disclosure restrictions at Tesla, I am unable to share details of my work, including CAD designs, prototypes, specific projects, & manufacturing processes. This means my portfolio only showcases prior work.

I do however encourage you to inquire about the skills I have demonstrated & developed over my fruitful work term!

Ask me about...

Precise tooling, fixture, & jig design
GD&T, datum selection, & tolerance analysis
DFM / DFA
Process capability, gauge repeatability & reproducibility
PLC programming automated manufacturing equipment
Computer vision

What would you like to see first?

Automation & Controls CAD & Simulation Electromechanical Systems Design

Portfolio

Automation & Controls

PLC Adhesive Control Stabilization 🎛️

Project

Re-engineered adhesive dispensing system producing 14/28 defective glue bands
Integrated new PLC ladder logic, HMI features, and redesigned dispensing system

Process

Developed Toyopuc PLC ladder logic integrating a Keyence laser displacement sensor to automate adhesive height inspection, enabling in-line quality validation by faulting out sub-spec segments ( <5mm)
Integrated new failure mode into HMI screen / buzzer to inform operator of defect without compromising cycle time
Conducted root cause analysis to isolate failure mode (under-dispensing due to inadequate system configuration rather than bad part fit)
Increased dispense volume from 30 cc → 65 cc through pump system rework, upgraded nozzle diameter (2 mm → 3 mm), & reprogrammed robot pathing (+2 mm standoff) to achieve adhesive height spec

Result

Completely eliminated defects (14/28 → 0/28)
Increased process robustness through automated PLC quality checks with no impact on cycle time

Computer Vision Reconfiguration 🤖

Project

Optimized OMRON vision inspection system used to verify adhesive on door panels
High false NG rates were causing line slowdowns, manual rechecks, and increased cycle time

Process

Diagnosed false failures by reviewing image histograms, lighting variation, and thresholds for NG classification
Implemented region-of-interest masks to isolate true bead paths and ignore fixtures/background noise
Applied RGB filtering and contrast/noise tuning to improve bead segmentation under variable lighting conditions
Adjusted detection tolerances and defect logic to distinguish part variation with actual defects

Result

Reduced nuisance NG calls by 85%
Eliminated most manual visual rechecks leading to 5 sec cycle time decrease
Recovered lost throughput by reducing vision scan delays and line holds

CAD & Simulation

Mirror Mount Neck Optimization 🪞

Project

Mount consisting of 6061 - T6 aluminum handle & PLA mount
FEA model with realistic hand-grip fixture & distributed load of mirror weight to simulate actual use

Process

Applied local mesh refinement at neck fillet to capture peak stress without over-meshing
Performed mesh convergence study to ensure accurate stress readings at critical points
Toleranced 3D-printed insert with .5mm offset to achieve reliable slip fit

Result

Decreased maximum stress by 93% upon selection of optimal design (21.62 → 1.390MPa)
Achieved first-pass functional slip fit between printed mount & aluminum tube

Door Install Alignment Jig 🧩

Project

Custom inspection fixture for verification of door alignment
Designed for ergonomic mounting & rapid installation onto existing metrology tools

Process

Produced detailed GD&T drawing with datums, positional tolerances, and profile controls to ensure part-to-tool alignment
Dimensioned critical interfaces to control probe location relative to door datum surfaces
Fabricated via FDM 3D printing

Result

Reduced setup time by 5 sec by eliminating possible positioning errors
Low-cost repeatable fixture compatible with existing micrometer tooling

Weld Position Verification Gage 🛠️

Project

Inspection gage to verify position of safety-critical welds

Process

Deployed cylindrical / diamond pin locating scheme to constrain 6 DOF while avoiding over-constraint from hole tolerances
Integrated insertion depth stops to ensure consistent seating and prevent over-insertion
Modelled through Solidworks surface modelling toolbox and produced the gage via FDM 3D printing

Result

Enabled repeatable verification of weld placement relative to critical datums
Reduced operator variability and improved inspection consistency

Electromechanical Systems Design

Piano Playing Robot by Colour 🎨

Project

Lego EV3 system that translates customizable colour sequences into piano key presses with colour sensor & RobotC
A need exists for individuals to create music without dexterity or knowing how to play an instrument.

Process

Developed four-finger key actuation system with two fingers per motor to minimize motor count under EV3 I/O constraints
Designed 3D-printed gear + belt conveyor with modular tile hooks for easy sequence reconfiguration
Implemented laser-cut acrylic/plywood mounts for subsystem alignment, wire routing, and motor concealment
Programmed C++ functions for colour-to-note mapping, tempo control, and arrays for automated sheet music generation.

Result

Achieved 95% note interpretation + execution accuracy
Executed multi-cycle operation without motor stall or program failure
Fully functional prototype that is easy to use and under $60 budget constraint
Next steps: 1 actuator per key for simultaneous presses, light mount for more accurate colour scanning

Colour Cruiser Boat Toy ⛵

Project

Locomotive boat that uses DC & servo motors for propulsion and rudder steering apparatus
Dual servo-operated doors that dispense bath dye into water

Process

Integrated DC motor + pulley drivetrain to keep motor above waterline while submerging propeller
Designed 3D-printed rudder with rounded hinge linkage for optimized hydrodynamic performance
Arduino-controlled three-servo architecture for rudder oscillation + dual-door dispense chamber
Managed mass distribution and component elevation to maintain buoyancy and prevent submersion

Result

Stable autonomous propulsion at 5 cm/s with consistent thrust
Reliable ±45° rudder steering producing non-linear pathing
Functionally isolated systems that execute core functions without brownout.

Skills

Technical skills

CAD/Sim

SolidWorks
NX
GD&T (ASME Y14.5)
AutoCAD
FEA (Static/stress)
Simulink

Controls & Automation

PLC (Toyopuc)
Machine vision (OMRON / Keyence)
Kawasaki/Nachi robotics

Manufacturing

3D printing (FDM)
DFM/DFA
Waterjet
Laser cutting
Machine shop

Programming

Python
MATLAB
C++
Arduino
RobotC

Contact

What are you waiting for?

linkedin.com/in/ava-keras

akeras@uwaterloo.ca