Lutron Electronics Co-op

Overview

During my six-month co-op at Lutron Electronics, I joined the tool design team responsible for developing manufacturing and assembly tools for the Ketra D2 Downlight product line. This experience transformed my approach to engineering design, teaching me that successful tools must balance technical precision with human factors and manufacturing realities.

Note: Tooling designs are under NDA. The image shown is of the Ketra D2 Downlight product I designed fixtures for. I am happy to walk through my design process and tooling work in conversation.

5

Tools Developed

2

Tools Certified & Deployed

10+

Tolerance Stack Components

Product Focus: Ketra D2 Downlight

Learn more about the Ketra D2 Downlight →

Exploded view of the Ketra D2 Downlight, the product I designed tooling and testing fixtures for

Engineering Contributions

Primary Tool Development

The Ketra D2 Downlight housing assembly represented one of the final and most critical steps in the production line. I designed a specialized tool to ensure precise component placement within the rectangular enclosure while protecting sensitive electronics and maintaining strict tolerances across more than 10 interfacing parts.

Design Process & Collaboration

Product Team Integration: Regular meetings to understand all assembly scenarios and edge cases
Manufacturing Engineering Partnership: Collaborated on operator workflows and ergonomic requirements
Operator Feedback Integration: Conducted observational studies and incorporated direct feedback from assembly line operators
Interactive 3D Modeling: Developed dynamic models in Creo Parametric to simulate tool motion and interaction

Technical Achievements

Tolerance Management: Designed to accommodate cumulative tolerances across 10+ stacked components while maintaining ±0.005" positioning accuracy
Component Protection: Incorporated soft-touch surfaces and controlled contact points to prevent damage
Ergonomic Design: Optimized handle placement and weight distribution for 8-hour shift comfort
Poka-Yoke Implementation: Integrated mistake-proofing features that made incorrect usage physically impossible

Note: Detailed tooling designs are under NDA. I am happy to walk through my design process and reference the product architecture in conversation.

Additional Tool Development

Beyond the primary housing assembly tool, I developed four additional fixtures for smaller component assemblies. These projects provided valuable experience in rapid iteration through 3D printing, design for manufacturability, and cost optimization while maintaining quality standards.

Professional Development

This co-op deepened my understanding of tolerance analysis, design for manufacturability, and how to communicate technical decisions across engineering and production teams.

Collaboration & Documentation

I partnered with manufacturing engineers to translate designs into producible solutions and developed comprehensive documentation for all tools, including assembly procedures, maintenance schedules, and design rationale, to ensure continuity after my co-op ended.

Skills Developed

Advanced CAD proficiency: Complex assembly design in Creo Parametric
Developed strong tolerance stack analysis skills through iterative design and peer review
Advanced 3D printing techniques (SLA/FDM) for rapid prototyping
Design for Manufacturing: Understanding of injection molding and assembly line constraints
Cross-functional Communication: Translating technical concepts for diverse stakeholders
User-Centered Design: Incorporating operator feedback into engineering solutions

Tools & Technologies

Creo Parametric 3D Printing (SLA/FDM) Tolerance Analysis Motion Simulation Design for Manufacturing Ergonomic Design Poka-Yoke Rapid Prototyping Project Management Technical Documentation