Spencer Blahey
Mechanical Engineer • San Francisco, CA
An engineer focused on turning complex problems into elegant, ship-ready solutions. I blend mechanical rigor with product intuition to deliver first-build prototypes under tight timelines. I aim for builds that prove feasibility, reduce risk early, and look production-ready.
Product Strategy
CAD & Simulation
Rapid Prototyping
Build & Validation
Team Leadership
Daylight Laptop (Proof of Concept)
Product Design / Physical Prototyping
2 Months
Objective
Develop a self-contained laptop prototype to showcase novel display technology on a compressed timeline.
Constraints
Time - Expedited concept-to-first-build.
Team - Lightweight support from ID and EE.
Aesthetics - Production-quality look and feel.
HW Components - Fixed LCD, motherboard, battery.
Learnings
Took the prototype from ideation to first build; deepened HID integration, DFMA decisions, and packaging within tight envelopes.
Challenges
- Hinges: model fidelity and interference checks
- Electronics: packaging and cable management
- Fasteners: snap fits vs. inserts
- Manufacturing: iteration and tolerance stack-ups
- Usability: tactile feel, thickness, weight
Methods & Materials
- Sketching apps (Paper, Concepts)
- Soldering & harness work
- 3D printing (PLA, ABS, resin)
- CAD (SolidWORKS)
- Rendering (Blender)
- Project planning (Asana)
Takeaways
Delivered a functioning laptop that met the original objectives. Next iteration: reinforce structure, refine materials, and further tune for manufacturing and assembly.
Near Infrared (LLLT) Medical Device
Product Design / Physical Prototyping
1 Month
Objective
Build an investigatory NIR medical device for a University of Texas research group—portable, self-contained, and meeting energy intensity requirements to progress clinical trials.
Constraints
Self Contained - No external supply.
Ergonomic - Comfortable across head sizes.
Usability - Simple operation.
Battery/Duration - 30-minute runtime.
Temperature - Manage generated heat safely.
Background
Low-level laser light therapy (LLLT) devices are explored to mitigate stroke, myocardial infarction, and degenerative or traumatic brain disorders.
Challenges
- Thermals: skin-safe and PCB-safe heat transfer
- Electrical packaging: cable routing and retention
- Procurement: cost and availability
- Fit: children through adults
- Usability: materials, thickness, weight
Methods & Materials
- Sketching apps (Paper, Concepts)
- Soldering
- 3D printing (PLA, ABS, resin)
- CAD (SolidWORKS)
- Rendering (Blender)
- Sewing (industrial walking foot)
Takeaways
Delivered a functioning device that met NIR thresholds and design goals. Next up: conceal more electronics, improve comfort, and consider a small LCD for firmware updates.
Etch A Sketch 2.0 (In Progress)
Mechatronics / Software Development
3 Weeks
Objective
Develop a tablet housing reminiscent of Etch A Sketch—nostalgic form while exploring serial communication over the device’s pogo-pin interface.
Constraints
Aesthetics - Etch A Sketch-inspired.
Functionality - Intended outputs only.
Structure - Secure internal components.
Connection - Pogo-pin interface only.
Learnings
Blending mechanical, electrical, and software: housing design, electronics packaging, cable routing, and an Android UI in Java/Kotlin.
Challenges
- Timeline: Expedited for content creation.
- Connection: Adapter for pin spacing.
- Fastener Design: Snap Fit, Threaded Inserts
- Software: App to recognize & share data.
Methods & Materials
- Soldering
- Accelerometer Data Retrieval
- Shake Algorithm Development
- Rotary Encoding
- Serial Communication
- USB Detection/Disconnection
- 3D Printing (PLA, ABS, Resin)
Takeaways
A functioning, lighthearted, physical demo, proving the connect-ability of a particular android device. Further, a quick turnover project tying together the diverse attributes of product design.
Ergonomic Workspace Design
User Research / Interface Design
2 Weeks
Objective
Improve usability of an outdated haul truck cabin through operator feedback, workspace data, and applied ergonomic design principles.
Constraints
Universal Design - Inclusive for all.
Hazardous Environment - Operator Safety.
Timeline - Expedited analysis.
Information/Data - Privatized industry data.
Learnings
Balanced diverse user needs with operational feasibility, using standards and guidelines to elevate safety and efficiency.
Challenges
- Inclusivity: Addressing user requests.
- NIOSH Standards: Meeting thresholds.
- Data Collection: Developing procedures.
- Lighting: Simulating accurate conditions.
- Space Optimization: Balancing constraints.
Methods & Materials
- User Interviews & Surveys
- Ergonomic Assessment Tools
- CAD Modeling Software
- NIOSH guidelines
- Mobile Data Collection
- Collaborative Software
Takeaways
The redesigned haul truck cabin significantly improves user ergonomics and safety, aligning with NIOSH guidelines for occupational health and injury prevention.
