Crew Tool

Design Engineer

Orlando, Florida September 2024 – September 2025

About Crew Tool

Crew Tool is a precision tooling startup specializing in aerospace manufacturing support. The company develops custom tools for sealant application and removal, designed to meet strict aerospace industry standards. Working at Crew Tool meant operating in a highly regulated environment where precision, quality control, and compliance were paramount to every design decision.

Modular Scraper Handle System

Designed a versatile handle system for interchangeable scraper heads used in aerospace sealant removal. The design featured a click-in-place mechanism that allowed operators to quickly swap between different scraper types without needing multiple complete tools.

Created CAD models following ASME Y14.5 standards for dimensional accuracy
Developed interlocking geometry to ensure secure attachment under operational loads
Designed for ergonomic comfort during extended use on the shop floor
Compatible with multiple scraper blade configurations for different applications

Design Assessment & Reverse Engineering

As part of the hiring process, I completed a practical design assessment that demonstrated core mechanical engineering skills. Given a physical scraper tool, I reverse-engineered it using precision measurement tools, then created a complete CAD model and manufacturing-ready technical drawing.

Measured complex geometry using calipers to capture accurate dimensions
Modeled the part in SolidWorks based on physical measurements
Generated a complete manufacturing drawing with proper tolerances and title block
Applied ASME Y14.5 standards for dimensional and geometric tolerancing
Demonstrated ability to translate physical parts into producible documentation

Precision Application Brushes

Modeled custom brushes for controlled sealant application in aerospace assembly environments. These tools were designed to meet Spirit AeroSystems specifications, ensuring consistent material application while maintaining operator control.

Generated detailed 3D models for manufacturing and documentation
Ensured designs met aerospace-grade material and tolerance requirements
Coordinated with manufacturing to verify producibility
Maintained compliance with industry quality standards

Technical Documentation & Drawings

Produced detailed technical drawings following ASME Y14.5 standards for aerospace tooling fabrication. These drawings served as the primary communication between design intent and manufacturing execution, ensuring precise dimensions and tolerances were maintained throughout production.

Generated manufacturing drawings with complete dimensional specifications
Applied geometric dimensioning and tolerancing (GD&T) principles
Created assembly documentation showing part relationships and installation procedures
Maintained drawing revision control and change documentation

From Design to Reality

The culmination of CAD modeling, technical documentation, and quality verification resulted in production-ready tools used on aerospace manufacturing floors. These custom scrapers demonstrate the full cycle from concept through fabrication, ensuring designs were not only functional but practical for daily operator use.