My Engineering Portfolio

1. Kyle Walker
Engineering Design Portfolio

2. Hello and welcome! Thank you for viewing my portfolio! It
is a sampling of some of the projects I’ve been a part of and
is designed to give you a greater understanding of my skills,
experiences, and who I am as a person.
I am happy to answer any further questions you may have
so please don’t hesitate to contact me using the
information at the bottom right of this page.
Welcome!
Kyle Walker
Kyle91w@gmail.com
linkedin.com/pub/kyle-walker/60/436/586/

3.  Flextrack
 777x Wing and Spar Lamination
 Flexible Biopsy Needle
 Gyrotonic Lift Kit
 Cryptex
 Cryptex 2.0
 Activities!
Contents
Kyle Walker
Kyle91w@gmail.com
linkedin.com/pub/kyle-walker/60/436/586/

4. Flextrack
Description: Automated 5 axis drillers for Boeing
and Embraer
Company: Electroimpact
Date: June 2016 – Present
My Roles: Programming, Mechanical Assembly,
Customer Liason
What I’ve Learned: Developed skills in human
interface design, debug, and programming with
C#, Macros and Fanuc Ladder; Expanded hands-on
knowledge through mechanical assembly tasks;
gained customer relations experience during
multiple onsite support trips
Project Info

5. 777x Wing and Spar
Lamination
Description: 6 axis Automated Fiber Placement
machine for Boeing
Company: Electroimpact
Date: June 2015 – June 2016
My Roles: Mechanical Assembly and Design
What I Learned: Developed hands on engineering
skills by working in a team environment to
construct large scale robotic systems for Boeing;
performed design tasks using Solidworks;
generated part drawings; worked directly with
machine shops to have my parts fabricated;
Link:
https://www.seattletimes.com/business/boeing-
aerospace/massive-speedy-robots-ready-to-build-
composite-wings-for-boeing-777x/
Project Info

6. Flexible Biopsy Needle
Purpose: Senior Design Project
Date: Sep 2013 - June 2014
My Role: Team Lead, CAD Designer, Machinist
Objective: Develop a flexible biopsy needle
capable of extracting core samples from tumors
located in the peripheral regions of the lungs [I].
Prior Method: Needle travels through skin and
muscle to access tumor [II]. This is highly invasive
and risks lung collapse.
Challenges: The needle needed to be flexible
enough to access the tumor transbronchially via
the bends of a bronchoscope [I] yet rigid enough
to pierce the tissue.
Project Info
I II
III
Compatibility Flexibility Sample Quality
Design Considerations

7. Flexible Biopsy Needle
Final Design: The needle was manufactured from
highly flexible polycarbonate.
Two needle designs were proposed, each being
equipped to handle different tissue types.
The saw tooth profile [I] shears the sample from
the body with an applied twist.
The loop profile [II] utilizes a fine kevlar strand
that is threaded through the two smaller channels
to form a loop at the end. Upon tightening the
strand, the loop closes and severs the tissue.
Final Design I II

8. Flexible Biopsy Needle
Drawing: To address the difficulty of machining
such small features, we adopted a drawing process
to prototype the needle.
We created large scale, versions of the needle in
the machine shop. These preforms were then
heated to their glass transition temperature and
stretched until they reached the desired diameter
[I] ,[II].
Saw Tooth Profile: The teeth were cut into the
preform using a linear broaching process [III and
inset].
Loop Profile: A three axis mill and 12” long drill
were used to carefully drill the channels for the
Kevlar wire [IV].
Prototyping
I
Computer controlled
vertical slide
Electric heating
element
Take-up reel
II
III IV

9. Flexible Biopsy Needle
Recognition: Our team was selected by the
University of Washington’s ME Department faculty
to receive the 2014 Outstanding Design Award.
We were chosen above all other ME Senior design
teams in our graduating year.
After our final presentation, our team was also
invited to present before the ME External Advisory
Board, a group of industry leaders who advise the
department chair on policy matters.
Key Skills: CAD, Product Design, Prototyping,
Milling, Lathing, Leadership, Teamwork and
Presentations
Outcome

10. Gyrotonic Lift Kit
Purpose: Class Project
Year: 2013
Project Duration: 8 weeks
My Role: Team Lead, CAD Designer
Objective: Design an aftermarket kit for the
Gyrotonic exercise bench that will allow for
independent adjustment of both ends of the
bench.
Final Design: A crank is used to ratchet in the
adjustable supports to raise the bench.
Key Skills: CAD, Product Design, Leadership,
Teamwork, Presentations
Project Info

11. Cryptex
Purpose: Personal Project
Year: 2008
Project Duration: 4 weeks
Objective: Build a Cryptex!
Background: A Cryptex is a cylindrical codebox
with a series of rings that rotate around the main
body. The alphabet is inscribed upon each ring,
and when the correct password is aligned, the
Cryptex will open.
The Cryptex was featured in Dan Brown’s 2003
novel The Da Vinci Code, and was allegedly
designed by Leonardo Da Vinci.
My Cryptex was inspired by The Da Vinci Code,
however, my design is an original work which I
devised and constructed independently when I
was sixteen.
Project Info
Misaligned Aligned
Closed Open
Locked Unlocked

12. Cryptex
Fabrication: The shapes of the inner cylinder and
outer rings were created using a hole saw, and
several bits of different sizes [I].
A Dremel was used extensively for carving in the
letters on the rings and forming the niches and
grooves of the locking mechanism [II].
Key Skills: Solidworks, Product Design,
Woodworking, Power Tools (Dremel, hole saw and
chop saw especially)
Fabrication and Finished
Product
I
III IV
II

13. What I learned from the Cryptex
 Engineering is fun!
 I discovered the thrill of bringing an idea from
concept to reality.
 I became familiar with design and fabrication
processes.
 I developed proficiency with various tools:
 Chop, Skill, Table, and Hole saws, Dremel,
Grinder, Sander etc...
 Most importantly: I learned that I wanted to
spend my life creating things.

14. Activities!

15. Hiking and
Backpacking!

16. Painting!

17. Swing Dancing!

18. Rock Climbing!

19. Thanks again for taking the time to consider my
portfolio! I appreciate the opportunity, and I hope you
have a great day!
Kyle Walker - Kyle91w@gmail.com - linkedin.com/pub/kyle-walker/60/436/586/