Mechanical & Aerospace Engineer

Hi, I'm Alvin Reji

I'm a mechanical engineering student with a problem solver's mindset and a pull toward aerospace, designing next-generation defense, aerospace, and medical device systems. From RF geo-locators to cardiac pumps, I bring precision engineering and inventive thinking to complex challenges.

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The PDF portfolio is an older snapshot. For my current work, scroll down to the Projects section below.

Alvin Reji
Aerospace Systems
Mechanical Design
Systems Engineering
Get to Know Me

About Me

I'm a Mechanical Engineering student at Northeastern University with a passion for aerospace systems, robotics, and medical device innovation. I've accepted a co-op offer to join Blue Origin in Cape Canaveral, FL starting Spring 2027, continuing to build toward a career in mechanical engineering within aerospace.

My engineering journey combines rigorous technical analysis with hands-on prototyping and real-world problem solving. From designing CubeSAT components and RF geo-locator systems to developing surgical implant hardware at Johnson & Johnson MedTech, I thrive on projects that push the boundaries of what's possible.

With experience spanning aerospace, defense, materials research, avionics, and medical devices, I bring a multidisciplinary approach to engineering challenges. I'm constantly learning, building, and seeking opportunities to create meaningful impact through technology.

Technical Skills

SolidWorks Ansys MATLAB Python C++ FEA CFD CAD GD&T Creo AutoCAD Altium Minitab MagicDraw MS Office GSuite

Hardware

3D Printing CNC Routing ShopBot Laser Cutting PCB Design TIG Welding Soldering Circuit Design Oscilloscope Microcontrollers
Academic Background

Education

Aug 2024 - Dec 2027

Bachelor of Science in Mechanical Engineering

Northeastern University

CubeSat Development: Designed critical components for a 1U satellite, ensuring modularity and structural feasibility while adhering to mission constraints.

Flight Avionics: Acquired expertise in initiating serial communication between sensors and microcontrollers, enhancing system integration and data acquisition.

TAMID: Member of Consulting Track. Conducted research and analysis to provide reputable advice to CEOs.

InterVarsity Christian Fellowship: South Asian InterVarsity (SAIV).

AerospaceNU TAMID InterVarsity
Aug 2023 - May 2024

Mechanical Engineering

University at Buffalo

University Nanosatellite Program: Member of the Guidance, Navigation, and Control Subsystem for the POLAR Satellite Mission, supported by the AFRL. Developed Interface Control and Design Documentation and performed satellite pointing simulations using MATLAB.

Solar Splash Electric Racing: Electrical Lead responsible for designing and implementing the power system configuration. Optimized solar panel setup to ensure maximum efficiency and performance.

Completed freshman year of undergraduate mechanical engineering program.

Nanosatellite Program Solar Splash Racing
Sep 2019 - Jun 2023

High School Diploma

New Hyde Park Memorial High School

Honor Roll NASA TechRise
Professional Journey

Experience

Blue Origin · Cape Canaveral, FL Starting Spring 2027

Aerospace Systems Engineer Co-Op Incoming

Accepted a co-op offer to join Blue Origin in Cape Canaveral, FL, continuing to build toward a career in mechanical engineering within aerospace.

Aerospace Co-Op
BAE Systems · Nashua, NH June 2026 - Aug 2026

Mechanical Engineering Intern

Collaborating cross-functionally with electrical, mechanical, and software engineers to resolve subsystem integration challenges within classified laboratory environments.

  • Developed Block Definition and Use Case Diagrams in MagicDraw to define system integration and user-product interactions
  • Designed locking mechanisms and cable management solutions for complex classified systems
  • Presented design reviews to customers, facilitating discussions to refine system design and meet stakeholder requirements
  • Led hardware development for an IP53-rated, multi-point RF geo-locator system, enabling successful location of a distress signal
Defense Systems Systems Engineering MagicDraw
Johnson & Johnson MedTech · Danvers, MA Jan 2026 - June 2026

Product Development Engineering Co-Op

Designed and iterated custom product components for Instron testing, supporting product verification efforts across the development lifecycle.

  • Designed and iterated custom product components for Instron testing using FDM and SLA printing for product verification tests
  • Conducted 100+ mechanical tests simulating clinical-use conditions and optimized test method to improve variability by 73%
  • Performed statistical analyses using Minitab to execute TMVs and Gage R&R studies for data-driven design improvements
  • Developed a Python/OpenCV pipeline to automate analyses across 30+ experimental iterations, improving design efficiency
  • Authored engineering documentation, test protocols, and work instructions ensuring compliancy, traceability, and consistency
Medical Devices Product Development Testing & Analysis
Massachusetts Institute of Technology Aug 2025 - May 2026

Teaching Assistant

Educated 24 students on iterative design process and Six Sigma quality concepts. Fostered collaborative classroom environment through conflict resolution coaching and led student teams through structured design projects.

Education Design Process Leadership
AerospaceNU - CubeSAT Team Sep 2024 - Dec 2025

Mechanical Engineer

Designed optical component casings for 1U CubeSAT using FEA analysis and DFMA principles. Generated GD&T-compliant engineering drawings and fabricated prototypes using FDM and SLA 3D printing.

Aerospace CAD FEA
AerospaceNU - Rocket Team Sep 2024 - Dec 2025

Avionics Engineer

Developed flight computer software and designed PCBs optimized for EMI compliance. Implemented signal processing for reliable sensor data acquisition.

Avionics PCB Design Embedded Systems
Northeastern University Sep 2024 - Present

Materials Engineering Research Assistant

Operated volumetric DIW 3D printers with micron-level precision. Designed and fabricated 30+ experimental samples for adhesive properties research.

Research 3D Printing Materials Science
Solar Splash Electric Boat Racing Aug 2023 - May 2024

Electrical Subsystem Lead

Led 7 engineers in designing electric boat power system. Achieved full NESC safety compliance and reduced costs by $7,000 through design optimization.

Leadership Power Systems Team Management
My Work

Featured Projects

This is my up-to-date, interactive portfolio, kept current as new projects wrap up.

ATLAS Direction Finding System
Defense Systems 2026

ATLAS – Direction Finding System

Led hardware design for a direction-finding system, from component selection to a field-tested prototype, as Hardware Lead on an intern training project at BAE Systems built to practice the engineering design process on an accelerated timeline.

Mini Trash Compactor CAD Assembly
Mechanical Design 2025

Mini Trash Compactor

Led fatigue analysis and co-designed a dual-power-screw compaction mechanism for a six-person mechanical design course, verifying every component and connection by hand and by FEA.

Automated Heated Jacket
Biomimicry Personal Project

Automated Heated Jacket

A wearable that automatically regulates body heat using embedded sensors and heating zones, inspired by how emperor penguins survive the Antarctic cold.

CubeSAT Camera Bracket
Aerospace 2024

CubeSAT Camera Bracket

Engineered a flight-ready camera bracket for a 1U CubeSAT constellation, validated through FEA and vibration testing to survive launch and orbit.

Avionics Flight Computer
Electronics 2024

Avionics Flight Computer

Built a custom flight computer PCB with real-time telemetry, flight-proven aboard a test rocket launch from circuit design to touchdown.

Guidance, Navigation & Control Satellite Simulation
Aerospace 2024

GN&C Satellite Simulation

Designed and validated spacecraft attitude control algorithms in MATLAB, stress-tested across 40+ Monte Carlo simulations for mission-ready reliability.

Horse Racing Real-Time Tracking Collar
Robotics 2024

Horse Racing Tracking Collar

Engineered a wearable IoT tracker that streams live motion data from a moving subject, from embedded sensor fusion to a custom analytics dashboard.

NASA TechRise High Altitude Balloon
Aerospace 2022

NASA TechRise High Altitude Balloon

Built and flew a high-altitude research payload selected for NASA's national TechRise challenge, capturing atmospheric composition data across multiple layers.

Microstructure Adhesive Properties Research
Research 2024

Microstructure Adhesive Properties

Investigated how microscopic structural patterns affect adhesion, using precision 3D-printed test structures to advance soft-materials research.

Let's Connect

Get in Touch

Interested in collaborating on engineering projects or discussing opportunities? I'd love to hear from you.

Email

reji.alv@northeastern.edu

Location

Boston, MA

LinkedIn

linkedin.com/in/alvin-reji