Let Kai build at CMU
Application microsite for CMU M.S. in Mechanical Engineering – Applied Advanced Study (Design and Manufacturing).
I want to design intelligent physical systems that people trust, wear, and rely on every day.
01
Context
The future of human-computer interaction is moving into physical space. We're moving beyond screens and keyboards toward devices that understand context, anticipate needs, and integrate seamlessly into daily life.
I see this shift happening in wearables, ambient devices, and assistive technology, where the hardware itself becomes the interface. The challenge isn't just building something that works in a lab; it's designing systems that people actually want to wear, trust, and rely on day after day.
This is where mechanical engineering meets human-centered design. It's about understanding thermal constraints, material properties, ergonomics, and manufacturability, not as afterthoughts, but as core design requirements from day one.
02
Motivation
Prototypes don't become products. I've learned this firsthand building hardware: what works on a breadboard fails in real-world use. What looks good in CAD breaks after a week of wear. What seems intuitive in testing becomes frustrating when people are tired, distracted, or just trying to get through their day.
The gap between prototype and product is massive:
- Reliability: Devices need to work consistently, not just when conditions are perfect.
- Ergonomics: Comfort over hours and days, not just minutes. Form factors that feel natural, not intrusive.
- Manufacturability: Designs that can be produced at scale with consistent quality and reasonable cost.
- Trust: Users need to believe the device will work when they need it most, which means it has to work every time.
Most hardware projects fail at this transition. They solve the technical problem but miss the human one. I want to bridge that gap.
03
How I've Prepared for CMU
Onvoice (Founder)
Built a live-event assistant that streams speech to attendees in real time for accessibility and engagement. Shipped pilots across multiple organizations, participated in GC Angels Accelerator (12% acceptance rate), received ~£5.75k funding, and iterated based on real user feedback.
Outcome: Product-led iteration with real users, understanding the gap between technical capability and user needs.
Wearable AI Microphone Prototype (Project)
Built a wearable device with ESP32-S3 + INMP441 microphone, focusing on always-available interaction. Electronics stack includes PCB design, battery management, power regulation, touch sensors/LEDs, USB-C + CP2102, boot control. Device communicates with PC/phone app.
Key realization: Prototypes are easy. Production-ready devices require mechanical design, thermal management, tolerances, materials, ergonomics, reliability, and manufacturability, all things I need to learn systematically.
LGS TECH (Founding Electronic Engineer)
(Applied power, sensing, and reliability at scale)
Worked on electronics and system design for safety-critical, long-lifecycle hardware. Contributed to PCB design, enclosure constraints, and system integration where small electrical decisions propagated into manufacturability, servicing, and long-term reliability.
Outcome: Learned how industrial hardware is less about clever circuits and more about traceability, robustness, failure modes, and design decisions that survive years, not demos.
Autonomous Buggy (Embedded System Competition)
(Sensing, control, and real-world autonomy)
Built and iterated on an autonomous buggy platform integrating embedded control, sensor fusion, and real-time decision making. Worked across firmware, electronics, and system integration to get a physical agent to behave reliably in an unpredictable environment.
Key realization: Autonomy breaks at the boundaries: timing, calibration, noise, and physical dynamics matter more than algorithms. Real systems force you to respect latency, uncertainty, and hardware limits.
Undergraduate Academic Performance
BEng (Hons) Electronic Engineering, University of Manchester
Outstanding performance in embedded systems, digital design, and electronics:
04
Why CMU
Carnegie Mellon's M.S. in Mechanical Engineering – Applied Advanced Study (Design and Manufacturing concentration) gives me the structured, system-level training I need to turn embedded prototypes and wearables into reliable, manufacturable products. The program combines advanced mechanical design, CAD/CAE, precision manufacturing, and mechatronic systems with a strong emphasis on real-world implementation.
The Courses
- 24-683 – Design for Manufacture and the Environment: Helps me design hardware that can actually be produced at scale while accounting for cost, reliability, and sustainability.
- 24-686 – Special Topics in Advanced Mechanical Design: Deepens my understanding of advanced mechanical structures and assemblies for production-grade devices.
- 24-688 – Introduction to CAD and CAE Tools: Strengthens my ability to move from concept to detailed 3D models and simulations, critical for enclosures and mechanical parts.
- 24-671 – Special Topics in Design and Manufacturing: Connects mechanical design with embedded systems and prototyping, which aligns with my embedded + hardware background.
- 24-753 – Principles of Soft-Matter Machines & Electronics (Soft Machines Lab): Directly relevant to my wearable AI device and my interest in soft, body-worn hardware.
The Ecosystem
TechSpark (College of Engineering makerspace): CMU's central makerspace for engineering students, with access to CNC machining, 3D printing, electronics labs, and fabrication tools. It's where I can iterate on my wearable hardware and embedded systems with professional-grade equipment and staff support.
Mechanical Engineering Labs & Shop Spaces: Department facilities that support prototyping, testing, and validation for mechanical systems and devices.
Soft Machines Lab (Prof. Carmel Majidi): Focuses on soft robotics, wearable devices, and human-compatible machines and electronics – perfectly aligned with my wearable AI project and interest in body-worn hardware.
Integrated Innovation Institute / Design Innovation (Prof. Jonathan Cagan): Brings together engineering, design, and business to create new products and services, and studies how teams make design decisions and create products people love.
Swartz Center for Entrepreneurship: CMU's hub for student and faculty startups, providing mentorship, seed funding opportunities, and connections to the Pittsburgh and global tech ecosystem. Project Olympus is an incubator that helps early-stage ideas move from concept toward commercialization.
I want to contribute as someone who can bridge embedded engineering and human-centered product realization. I've built the electronics and firmware; now I need the mechanical engineering depth to make it manufacturable, reliable, and truly human-centered.
05
What I'll do there
Build
Use TechSpark and Mechanical Engineering labs to iterate on my wearable hardware: better enclosures, improved thermal management, robust assembly, and soft, body-compatible structures inspired by the Soft Machines Lab.
Validate
Apply design and manufacturing methods from 24-683, 24-686, and CMU's design courses to run structured tests with users—measuring comfort, trust, and reliability, and feeding that back into design decisions.
Realise
Use what I learn about design for manufacture and product realisation to move from prototype to manufacturable system, while exploring commercialisation pathways through the Swartz Center and Project Olympus.
PROJECTS
Relevant Projects
Autonomous Line-Following Buggy
ARM-based autonomous vehicle system designed for high-performance operation under real constraints. University research project focused on system integration.
Wearable AI Microphone Prototype
ESP32-S3 based wearable device with always-available interaction, focusing on seamless human-computer interface.
BagAlert (Sony Hackathon - 1st Place)
A campus-focused loss-prevention system that detects unattended bags and alerts the correct owner in real time.
Onvoice
Live-event assistant that streams speech to attendees in real time for accessibility and engagement.
Branchify
A student-only marketplace designed to make buying and selling second-hand items easier, safer, and more trusted on university campuses.
Hardware Lifecycle Engineering - Light Guiding Systems Technology
Worked in a professional hardware startup environment contributing across electronics, mechanics, and system integration.
Robot Fighting Competition - Mechanical Redesign Under Failure
A competitive fighting robot designed, tested, failed, and redesigned through mechanical analysis and iteration.
Coupang Hackathon - User-Centered Product Concept
A product concept developed to address Coupang's limited penetration among Taiwanese youth through short-form video platform design.
AWARDS & RECOGNITION
Awards & Recognition
Autonomous Line-Following Buggy Competition - 1st Place
Achieved fastest lap time and highest technical score among 50 teams in EEE second year. Designed and fabricated an ARM-based autonomous vehicle system with custom PID control algorithm, achieving seamless integration of mechanical chassis, sensing systems, and embedded firmware. full report
Sony Hackathon - 1st Place
Built BagAlert, an AI-powered smart surveillance system for preventing theft of unattended belongings. Integrated ESP32 + RFID, Sony IMX500 AI camera, real-time detection, and live alert dashboard. official post from sony • hackster.io
Google Developer Student Clubs Hackathon - 1st Place
Developed accessibility-focused input systems using hand-tracking and eye-tracking. Built a scanning keyboard enabling text input with minimal physical interaction.
Masood Entrepreneurship Centre Startup Weekend - 2nd Place
Co-developed Branchify, a student marketplace focused on trust and sustainability. Progressed from problem discovery to business model and pitch within a single weekend.
GC Angels Accelerator
Selected into accelerator (12% acceptance rate) and received funding for Onvoice. linkedin post
ASK KAI
Ask me questions!
Ask me about my projects, goals, or why CMU is the right place for my next step. I'll answer based on what I've shared here.
Ask me about my projects, goals, or why CMU is the right place for my next step.
CONTACT
Get in touch
I'm excited about the possibility of contributing to CMU's Mechanical Engineering community—bringing my experience in building real products, learning from failure, and pushing wearable hardware toward reliable, manufacturable systems.
I'd love to hear from you, whether you have questions, want to discuss my projects, or just want to connect.