Parts Wall | Caterpillar Inc - Morton, IL

I led the design and execution of a 10x20 ft feature wall composed of 390 individually modeled parts, all additively manufactured. I was given a general theme and transformed it into a full visual installation. Developing the focal point, geometric layout, visual rhythm, and layered depth.

I also managed the fabrication logistics and physical installation, ensuring the final piece maintained consistency in form and tone across diverse materials and processes.

Role: Lead Designer

Medium: 3D Printing (SLS, FDM, SLA, and DLS) and CNC Router

Software: Creo and Materilize Magics

Size: 10ft x 20ft | Year: 2021 | Timeline: 5 months

A display of various yellow mechanical parts and gears organized inside a transparent case.
Display of various yellow mechanical parts and gears arranged on a large board.
Disassembled yellow plastic toy with various nuts, bolts, hooks, and other hardware parts scattered on a round surface.

Process

  • A detailed diagram of a racing track layout with annotations for elements like track width, track length, variable height, and gaskets angle parts. The diagram is drawn with black outlines and yellow highlights, placed on a sheet of paper on a desk. A silver pen and a ruler are also visible.

    Concept

  • A digital illustration of various mechanical and electronic components scattered across a yellow background, seen through a tilted screen frame.

    Model

  • Yellow mechanical parts and components on a gray workbench in a machine shop or manufacturing setting, with a blueprint or technical drawing nearby.

    Print and Assemble

  • A large yellow panel with various mechanical parts and gears attached, inside a warehouse with industrial lighting and equipment.

    Paint

C13D Full Scale 3D Printed Model Engine | Caterpillar Inc

I led the design and production of a full-scale 3D-printed engine model featured at Caterpillar’s engine booth during CONEXPO 2023, one of the largest construction expos in North America.

The model was built from real engine CAD data and reworked into print-ready subassemblies optimized for detail, durability, and efficient production. I managed the end-to-end workflow, coordinating builds across SLS, SLA, and DLS platforms, and oversaw a cross-functional team of engineers and suppliers.

The final display weighed over 400 lbs and featured over 300 individually electroplated fasteners and fittings, enhancing realism and visual fidelity. It served as the booth centerpiece, showcasing the scale and complexity of Caterpillar’s engine platforms through additive manufacturing.

Role: Project Manager and Designer

Medium: 3D Printing (SLS, SLA, and DLS) and Electroplating

Software: Creo and Materilize Magics

Size: 2x ~6ft tall and 400lbs

Year: 2022-2023 | Timeline: 3 months

Two large industrial engines, one silver and one yellow, displayed on metal stands in a modern indoor setting.
Close-up of a mechanical engine with visible belts, pulleys, and metal components in a workshop.
Close-up of a yellow industrial machine or engine with metal pipes, hoses, and black components, situated in a workshop or industrial setting.

The Process

  • Shelves with white and gray 3D-printed plastic parts, including engine components and mechanical parts.

    Print

  • A gray concrete or stone planter with plastic sheeting underneath, positioned on a workshop floor.

    Assembly

  • Large industrial engine block painted yellow and gray in a factory setting.

    Paint

  • Metal engine parts and bolts in front of a partially assembled engine block.

    Bolts

Wall Part Sculpture | Caterpillar Inc - Peoria, IL

Wall sculpture was inspired by the large parts wall but they wanted a simpler self supporting sculpture.

Role: Lead Designer

Medium: 3D Printing (SLA

Software: Creo and Materilize Magics

Size: 6ft long

Year: 2022-2023 | Timeline: 3 months

Arrangement of yellow gears and cogs of various sizes mounted on a dark gray wall.
Collection of yellow plastic gears and mechanical parts arranged on a dark grey surface.

Process

  • Colorful plastic gears and mechanical parts arranged in a scattered pattern.

    Model

  • White plastic gears and mechanical parts laid out on a beige work surface in an industrial setting.

    Print

  • White plastic gears and mechanical parts on a gray table, some assembled and some unassembled.

    Assembly

  • Various white plastic gears and mechanical parts laid out on a work table in an industrial setting.

    Paint

  • Sketches of various arrangements of circles, some filled in with yellow color, on a white sheet of paper, with markers nearby.

    Concept

The Parts Pillar | Caterpillar Inc - Belgium

I was brought in to lead the design of six sculptural panels featured in an international Caterpillar facility. The team provided a basic rendering and asked me to develop a full additive-based parts wall, one that would integrate visually with the surrounding mural and machinery while standing as a compelling design element on its own.

I created the layout and form language of the panels from scratch, selecting and arranging real components, shaping the depth and spacing of each section, and building a layered, spatial composition that brought structure and continuity across all six pillars. The goal was to convey complexity and motion while showcasing the structure and detail of the real components.

Once the design was approved, I prepared the CAD for build handoff. Printing, finishing, and installation were managed by a separate team, but the final outcome was shaped directly by my creative and structural design work.

A display wall showing yellow mechanical parts and gears illuminated by white backlighting, with three vertical slots in a modern setting.

Role: Lead Designer

Medium: 3D Printing (SLA and FDM)

Software: Creo and Materilize Magics

Size: 6 x ~5ft x 18in panels

Year: 2024 |Timeline: 1 month | Design time: 2 days

A modern interior with white walls and ceiling, featuring illuminated display cases with yellow gears and machinery parts, and a large digital screen showing a mountain landscape with a yellow excavator.
Display of yellow plastic mechanical parts and gears arranged within a gray frame with illuminated edges.
  • Diagram of mechanical parts including gears, chains, bearings, and brackets, organized within three vertical sections on a light blue background.

    Design

  • Assorted mechanical and electronic components, some in gold and gray, scattered on a white background.

    Labeling

  • Yellow workshop mold with various protruding shapes and geometric features on a worktable, next to a set of technical drawings and a cardboard box.

    Assembly and Paint

  • Display of large yellow gear mechanisms in a modern interior space with suspended ceiling and yellow and black seating in the background.

    Installation

  • Sketches of pie chart segments and patterns, some filled with yellow marker, with rulers and markers on a white surface.

    Concept

Smaller Projects

Gear Sculpture | All over Caterpillar Inc

Role: Lead Designer | Medium: SLS Nylon 12 with high-gloss Cat Yellow finish

This 18-inch-tall sculpture was designed as a three-part gear assembly that echoed the visual style and layered geometry of my larger wall installations. Modeled in Magics, the piece combined interlocking gear forms to create depth, mechanical texture, and visual motion in a compact format. The result was a small-scale statement piece that blended engineered precision with sculptural composition.

Three gear rings arranged vertically, with a close-up of their teeth and inner surfaces.
Three large white plastic gears stacked and intersecting against a black background.
Collection of gold-colored, gear-like mechanical parts with varying shapes and sizes, placed against a dark background.
A green potted plant on a metal stand with three large yellow gear-shaped objects in front of it.

Genset model | All over Caterpillar Inc

Role: Lead Designer | Medium: SLS Nylon 12

This 9-inch engine model was adapted from an existing design created by another team. My role was to redesign the geometry into a printable, paintable component that could be produced and finished efficiently at scale. I developed a custom part tree, inspired by injection molding runners, to streamline painting, improve part organization, and simplify assembly for multiple units. The result was a clean, two-tone painted display model with consistent quality and fast turnaround.

A detailed technical illustration of an aircraft landing gear assembly, showing various components including hydraulic cylinders, structural supports, and attachment points, in a transparent, rendered style.
Computer-aided design model of a large industrial engine or generator with blue and gray components, mounted on a base.
A blue technical diagram of a large industrial engine or machine with detailed components and piping.
Industrial machinery painted blue with various components and mechanisms for manufacturing or processing.
A blue industrial machinery or equipment with pipes and metallic components.

Award Stand | Caterpillar Inc

Role: Lead Designer | Medium: SLS Nylon 12 with high-gloss Cat Yellow finish, acrylic plate

I designed this sculptural base for an internal excellence award displayed in a Caterpillar office. Drawing from the same visual language I developed for a large-scale parts wall, I refined the geometry into a compact form with strong composition and layered depth. The base features a high-gloss Cat Yellow finish and a laser-cut acrylic plate to highlight the award element, creating a clean, branded display with a polished, engineered aesthetic.

3D illustration of a circular mechanical device with various screws, bolts, and nuts in gold color, with a textured outer rim.
A 3D model of a circular, honeycomb-patterned structure with multiple vertical walls extending upwards from the base.
Caterpillar Excellence award on a wooden display stand on a white table in an office environment.