KABAM Robotics
HALO 3
As a core mechanical engineer and vice product lead, I helped drive the full hardware development of HALO 3, KABAM’s flagship autonomous outdoor robot. I designed and engineered over half of the robot’s mechanical assemblies, focusing on structural robustness, internal packaging, sensor integration, and assembly efficiency.
My work involved building clean, parametric CAD in SolidWorks and CATIA, validating designs through rapid 3D-printed prototypes, and working directly with factory engineers in China to refine tolerances and manufacturability before production. I collaborated closely with navigation and AI teams to integrate LiDAR, cameras, IMU, GPS, and ultrasonic sensors while maintaining clear fields of view, reliable mounting, and efficient cable routing.
I also supported environmental testing and failure debugging, including water ingress and thermal-related issues, ensuring the final design was reliable for outdoor deployment and ready for production.
Matrix 1
I owned major mechanical subsystems and helped move the platform from an aluminum-frame mockup to a production-ready product. A key focus was thermal and environmental reliability. I designed and validated new cooling ducts and fan placements, testing performance under sustained outdoor heat while preserving waterproofing requirements.
I led water-jet testing, thermal soak testing, and mechanical stress validation, and resolved repeated water ingress issues through geometry changes, gasket strategies, and drainage paths without compromising DFA. I also addressed thermal expansion problems by refining material interfaces and clearances to maintain consistent mechanical performance at elevated temperatures.
I worked with navigation and AI teams on sensor placement, occlusion management, and mechanical envelopes for autonomy-critical hardware. I also collaborated with suppliers to improve DFA, streamline assembly sequencing, and reduce build time through better fastener access and part organization.
Photo blurred to comply with company rules.
Photo blurred to comply with company rules.
HALO 3 PROTOTYPE
This prototype represents a full internal redesign of HALO 3. Compared to the previous generation, all internal systems were replaced with a new proprietary architecture, the skateboard propulsion system was redesigned, and the overall platform was scaled by roughly 10% in all dimensions. These changes fundamentally altered the robot’s internal and external constraints and required a full re-architecture of the mechanical system.
I redesigned the core chassis structure and internal layouts, rebuilding sensor placement, electrical routing, thermal management, waterproofing strategy, and DFA from the ground up. I also led major updates to the bumper system, drivetrain architecture, crab-walk mechanism, suspension tuning, and camera geometry and housing design to support the new autonomy stack and expanded sensor suite.
This mockup was built by hand using 3D printing and aluminum framing to validate packaging, kinematics, serviceability, and assembly sequence before releasing designs for factory validation and production.