Karl Alexander Hackenbracht
Fort Wayne,IN
Summary
Highly ambitious manufacturing engineering intern with hands-on experience in design and process optimization. Expertise in applying engineering principles to create effective solutions while ensuring FDA quality standards. Adaptable to dynamic environments, with a commitment to continuous learning and professional growth. Achievements include implementing innovative strategies that enhanced efficiency and productivity.
Overview
3
3
years of professional experience
Work History
Lab Technician Assistant
Indiana Institute of Technology
Fort Wayne, IN
01.2023 - Current
- Effectively managed high-pressure situations, prioritizing tasks, and troubleshooting equipment issues to meet tight deadlines without compromising safety and quality.
- Operated and maintained 3D printing equipment, producing precise prototypes and parts; improved turnaround times for rapid prototyping requests by 10% to 20%.
- Streamlined lab workflows by implementing efficient preparation and setup procedures, reducing task completion time by 50%, and ensuring timely delivery of results for student and faculty projects.
Manufacturing NPI Engineering Intern
Zimmer Biomet
Warsaw, Indiana
05.2025 - 08.2025
- Ensured FDA compliance with manufacturing protocols and quality assurance standards.
- Operated Gage R&R equipment to maintain accuracy in titanium nail production.
- Created ECRs and secured approvals from multiple departments.
- Streamlined manufacturing processes by completing PFMEAs, updating work instructions, and tracking work orders.
- Operated UTE bending machine and evaluated parts for tolerance compliance.
- Reviewed defective parts and provided management with actionable feedback on root causes.
- Designed new bending dies using SolidWorks and NX.
Mechanical Engineer Intern
ASYST Technologies LLC
Kenosha, Wisconsin
05.2024 - 08.2024
- Facilitated international communication with Germany, Mexico, and USA, increasing warehouse storage by 25% through mold disposal.
- Conducted root cause analysis, implementing prevention plans that reduced repair downtime by 15%.
- Led project valued between $100,000 and $150,000 to assess lifecycle of 50 molds for budget optimization in 2025.
- Presented management with data-driven solutions for cost-effective mold replacement versus repair decisions.
- Aided in redesigning molds by highlighting stress concentrations.
Mechanical Engineer Intern
ASYST Technologies LLC
Kenosha, Wisconsin
05.2023 - 08.2023
- Collaborated with senior engineering team to lead project for upgrading injection molds.
- Implemented automatic cycle count system with molding engineers, decreasing data retrieval time by 10-15 minutes per mold.
- Utilized QAD to assess need for disposition or servicing in 100-150 molds.
- Recommended weekly inspections for molds nearing 1,000,000 cycles due to frequent failures.
- Held strong communication with molding, management, shipping, and finance to get tasks done on time.
Education
Bachelor of Science - Mechanical Engineering
Indiana Institute of Technology
Fort Wayne, IN05.2026
Skills
- SolidWorks (Modeling and FEA)
- NX and EAGLE
- Excel
- AutoCAD
- Root Cause Analysis
- CNC
- Design For Manufacturing
- Windchill PLM
- GD&T
- Lean Manufacturing
- Analytical Thinking
- Waste Reduction
- Process Validation (EQ and IQ)
- ISO 13485 and 9001
- Sterilization
- EOL
Projects
Self-Sorting Marble Machine:
Designed, Programmed, Tested, and Built an automated self-sorting marble machine. Utilized experience to select best material in order to achieve a 100% success rate even in random order.
Military Vehicle Cable Spooling Device:
Designed, built, and tested a spool that dispensed a certain amount of wire/string according to how many times the user pushed a button. This project was made to resemble the military vehicle wire spool and increase dispensing efficiency to reduce time in case of an emergency.
Extracurricular Activities
ASME Student Section Vice President:
Directed and coordinated executive meetings and initiatives, developing event schedules, workshops, and speaker panels to engage over 15 members and foster professional development. Acted as the primary liaison between the chapter and university administration, national ASME leadership, and local industry, ensuring clear communication and strengthening partnerships for student benefits.
Accomplishments
- Deans List Recipient (Maintained a GPA of 3.5+ consistently recognized for academic excellence).
- Vice President of ASME Student Body
- Teacher Assistant (Taught Additive Manufacturing and Labs)
Languages
German
Native/ Bilingual
English
Native/ Bilingual
Affiliations
- Honors Student at Indiana Institute of Technology
- Gene Haas Recipient Scholar
- Process Improvement Award at Indiana Institute of Technology
References
References available upon request.
Timeline
Manufacturing NPI Engineering Intern
Zimmer Biomet
05.2025 - 08.2025
Mechanical Engineer Intern
ASYST Technologies LLC
05.2024 - 08.2024
Mechanical Engineer Intern
ASYST Technologies LLC
05.2023 - 08.2023
Lab Technician Assistant
Indiana Institute of Technology
01.2023 - Current
Bachelor of Science - Mechanical Engineering
Indiana Institute of Technology
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