GREGORY MELONE
Hollis,NH
Summary
Mechanical and materials engineer with hands-on experience across metal additive manufacturing R&D, precision CNC machining, and full cycle vehicle design and fabrication. Proven track record building and characterizing novel hardware under real world constraints; from competition winning binder jet components to ground up custom motorcycle builds. Pursuing emerging field roles in energy, propulsion, and advanced hardware development where first principles thinking and manufacturing knowledge are significant.
Overview
7
7
years of professional experience
Work History
Design & Fabrication Engineer
Walt Siegl Motorcycles
Harrisville, NH
06.2023 - Current
- Integrated CAD-based design into an existing analog workflow, personally leading all computer generated chassis geometry and surface modeling for bodywork across multiple concurrent builds
- Spearheaded the full electrical system design and integration for ground up electric motorcycle builds, including motor control, battery systems, and wiring architecture
- Led in house engine control system tuning and diagnostics for combustion engine builds, analyzing in situ data from test rides, making program and map changes to optimize engine performance
- Employed 3D scanning of organic hand shaped forms to generate accurate computer models for body panels and frame components, bridging traditional fabrication and digital design
- Executed tight tolerance machining on the manual mill and lathe for rapid iteration prototypes, applying iterative design specific to each build and application
- Performed composite layups, and multi-process fabrication from raw materials through finished assemblies across weight optimized racing platforms
- Conducted structural analysis and tolerance studies on critical chassis components to validate designs before committing to production parts
- Bespoke high-performance motorcycle design and fabrication studio — custom Ducati race builds and full electric vehicle programs
Research Engineer Co-op
Desktop Metal
Burlington, MA
01.2022 - 09.2022
- Executed multivariable DOEs spanning process, materials, and design engineering for a novel metal AM system in active R&D; working directly on prerelease hardware not yet commercially available
- Led company wide CT scanning and scanning electron microscopy (SEM) programs for non-destructive inspection and failure analysis, designing custom fixtures for diverse part geometries
- Developed and deployed an autonomous CNC machining program to manufacture critical precision components in house, achieving tolerances under 10 microns while reducing lead time and part cost vs. external sourcing
- Collaborated directly with the SAE Clean Snowmobile team to demonstrate binder jet manufacturing of a 17-4 PH stainless steel exhaust manifold on the Shop System; part featured in a published Desktop Metal case study as a record setting performance application
- Metal additive manufacturing pioneer developing next-generation binder jetting and MHD-based systems
Undergraduate Research
22 Designs / Clarkson University
Potsdam, NY
09.2022 - 05.2023
- Partnered with ski binding manufacturer 22 Designs to investigate and resolve premature failure of a critical telemark binding bushing, with failure modes spanning cyclic wear during ski touring and brittle fracture under dynamic shock loading
- Developed custom test rigs to replicate both failure modes in the lab: integrated servo controlled hydraulic axial load frame for cyclic fatigue and wear simulation, and designed a separate impact apparatus to reproduce shock induced fracture; successfully recreating field failures under controlled conditions
- Conducted full materials investigation including microstructural analysis and wear characterization of the incumbent material; evaluated and fabricated candidate replacement materials, performed comparative testing, and delivered a formal recommendation to the company supported by quantitative performance data
President & Lead Engineer
SAE Clean Snowmobile — Clarkson University
Potsdam, NY
09.2019 - 05.2022
- Re-engineered a Caterpillar 1.1 diesel engine into a turbocharged configuration with custom electronic fuel control, achieving 1st place overall and record lowest emissions at SAE CSC in 2019 and 2022
- 3D printed a 17-4 PH stainless steel exhaust manifold using Desktop Metal's Shop System and Live Sinter software where the part operated at 1,250F under cantilevered load and aggressive vibration, printed in under 5 hours vs. a 2-week machined lead time; team awarded Best Technical Design
- Designed and implemented a custom electrical system with 0% failure rate across 3 competition seasons
- Led a team of 15+ engineers through project planning, fabrication, and competition execution
Education
Graduate Study, M.S. - Mechanical Engineering — Materials Concentration
Purdue University
West Lafayette, IN09-2026
Graduate Study, M.S. - Mechanical Engineering — Advanced Materials for Industrial Processes
Politecnico Di Milano
Milan, Italy07.2024
B.S. - Mechanical Engineering / Materials Engineering Minor / Advanced Manufacturing Minor
Clarkson University
Potsdam, NY05.2023
Skills
- SolidWorks, Fusion 360
- 3D scanning
- ANSYS, Abacus
- MATLAB, Python
- Metal binder jetting
- FDM
- SEM
- CT scanning
- Optical microscopy
- Custom fixturing
- CNC mill and lathe
- Mastercam & HSMWorks
- Manual mill and lathe
- TIG welding
- Composite layups
Timeline
Design & Fabrication Engineer
Walt Siegl Motorcycles
06.2023 - Current
Undergraduate Research
22 Designs / Clarkson University
09.2022 - 05.2023
Research Engineer Co-op
Desktop Metal
01.2022 - 09.2022
President & Lead Engineer
SAE Clean Snowmobile — Clarkson University
09.2019 - 05.2022
B.S. - Mechanical Engineering / Materials Engineering Minor / Advanced Manufacturing Minor
Clarkson University
Graduate Study, M.S. - Mechanical Engineering — Materials Concentration
Purdue University
Graduate Study, M.S. - Mechanical Engineering — Advanced Materials for Industrial Processes
Politecnico Di Milano