Welcome

My name is Samuel Belden, and I am a Materials Engineer at SpaceX working on providing high speed, low latency to the world with Starlink. I graduated from MIT several years ago with a Bachelor's Degree in Materials Science and Engineering. I'm primarily interested in mechanical design, materials selection, and aerospace. My focus in Materials Engineering so far has been in adhesives and polymers design/testing/selection, process engineering, materials reliability testing, and in bringing up mass production consumer electronics. I have been involved in various materials science projects and research in my time at MIT, ranging from lab work to hands-on prototyping and manufacturing.

I enjoy working on hands-on, challenging engineering projects, both as a hobby and as a career. I've built my own electron microscope that can 'see' atoms, made custom injection molded yo-yo's, and am working on building my own carbon fiber bike, along with various other projects. I'm always up to something.

Outside of school, I'm an avid backpacker, camper, hiker, rock climber, canoer, rower, cook, baker, and entrepreneur.

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Research Focus

  • Mechanics of Materials
  • Composites
  • Polymers and Adhesives
  • Mechanical Design
  • Additive Manufacturing
  • Consumer Electronics Mass Production
  • Process Engineering

Industry Experience

  • SpaceX - Materials Engineer II
  • Apple - iPhone Product Design Intern
  • CEiiA (Portuguese Aero Company) - Intern
  • Research in EEL Lab
  • Research in Grossman Lab

Other Interests

  • Camping/Backpacking/Canoeing
  • Cooking/Baking
  • Travel
  • Rock Climbing
  • Consumer Technology



While at Apple, I worked primarily on both the AirPower wireless charging mat and the next generation iPhone 8 and 8+. I designed and fabricated several test setups through collaboration with electrical engineering, materials, and product design teams for benchmarking technologies and conducting user experience studies. I extensively used NX CAD, ANSYS mechanical, thermal, and electromagnetic simulation software, and Matlab.

At CEiiA, I performed market analysis and research on battery managment system (BMS) options for a large 30kg UAV. I designed multiple BMS options in Eagle and had them manufactured and tested. I also performed several carbon fiber layups for another intern's 3-axis gimal design.



Skills - Computer

  • Siemens NX
  • Solidworks
  • ANSYS (Mechanical, Thermal, Electromagnetic)
  • Mastercam
  • PCB Software (Altium and Eagle)
  • Matlab

Skills - Tools

  • Mechanical Testing - Instron
  • Characterization (Raman, BET, XRD, SEM, DSC, STM)
  • Subtractive (Mill, Lathe, Laser Cutter, Waterjet)
  • Additive (FDM, SLA, SLS/M, DED, and DW)
  • Composite Design and Layup

Skills - Electrical

  • PCB Design and Fabrication
  • Soldering
  • Arduino
  • Oscilliscope
  • Sensors



Practical experience in



Composite Design and Layup

Have designed and laid up various projects in carbon fiber, fiberglass, and burlap - including motorcycle and racecar fairings, gimbal housings, bike frames and seats, and more

Product Design

Proficient in NX, Solidworks, Rhino, various FEA softwares, ANSYS Mechanical, Thermal, and Electromagnetic packages, Eagle, Matlab, and others. Interned on Apple iPhone Product Design Team

Manufacturing

Proficient in machining, 3D Printing (SLA, FDM, SLS/M, DED, DW), composite layup, casting, welding, thermoforming and injection molding

Casting, Welding, Metal Treatments

Worked extensively in MIT Forge casting metals, welding, and testing heat treatments. Took several metallurgy classes to supplement



Please email me for the most recent copy of my resume or if you have any questions. Thanks for looking!