Alex Cooper
Engineering & Fabrication Portfolio
Engineering Projects
NASA Human Exploration Rover Challenge (HERC)
Collaborated with a 32-student senior design team to engineer a man-powered rover and mechanical task tool for NASA's annual competition.
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- Designed and developed a specialized task tool capable of completing mechanical objectives along a half-mile technical course.
- Fabricated aluminum components using machine shop equipment, including belt sanders and mills, to ensure structural integrity.
- Optimized component geometries for rapid 3D printing and presented design concepts during formal project reviews.
Automated Environmental Data Logging System
Engineered a microcontroller-based automated irrigation and environmental monitoring system using an Arduino Uno architecture.
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- Integrated corrosion-resistant capacitive soil moisture sensors and thermocouples to record external environmental data.
- Developed and compiled C++ logic to export variables locally as Comma Separated Values (CSV) via a Data Logging Shield.
- Technology developed during this project is currently utilized by the university greenhouse for automated irrigation.
Cosplay Fabrication & Replica Props
The Batman (2022) Tactical Suit Replica
Fabricated an award-winning wearable cosplay replica utilizing 3D printing, EVA foam crafting, and custom textile tailoring.
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- Scaled, sectioned, and 3D printed the cowl and breastplate assemblies using PLA filament.
- Drafted patterns and sewed a custom tactical vest, integrating segmented EVA foam abdominal plating and adjustable strapping.
- Awarded Runner-up in Prop Design at Lowe Mill Comic Con and 1st In-Show at the UAH Comic Con.
Ghostbusters Replica Prop Suite
Engineered and assembled a full-scale replica Proton Pack, Ghost Trap, and PKE Meter over six months, integrating custom circuitry and mechanical switches.
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- Proton Pack: Designed and assembled utilizing 3D printing, laser cutting, and careful hardware selection.
- Ghost Trap: Upgraded base molds with functional toggle switches, internal LED illumination, and layered acrylic/toothpaste weathering for realistic metallic chipping.
- PKE Meter: Rewired internal DC motor controllers to manual toggle buttons, allowing for user-controlled mechanical actuation of the sensor arms.
The Mandalorian Armor Suit
Fabricated a custom wearable armor suit based on Din Djarin from The Mandalorian, utilizing 3D printing, surface finishing, and textile integration.
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- Manufactured rigid armor plating using modular 3D printed components, sanded and processed to achieve a seamless, metallic surface finish.
- Assembled underlying soft goods and flight suit materials to ensure comfortable articulation and accurate character silhouettes.
- Applied targeted weathering and distressing techniques to simulate real-world environmental wear and battle damage.
Spider-Man: Homecoming Modular Suit
Designed and constructed a breathable, modular cosplay focusing on custom fabric dyeing, textile splicing, and magnetic hardware integration.
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- Spliced and tailored athletic apparel to create a custom-fitted, two-tone hoodie, featuring hand-drawn iconography based on The Amazing Spider-Man designs.
- Engineered a 3D-printed internal faceshell paired with adjustable, magnetic mesh lenses for maximized airflow and structural rigidity.
Hardware Modification & Production
Gameboy Color Modernization Mod
Executed micro-soldering and hardware modifications to restore and modernize a legacy electronic gaming console.
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- Desoldered a deteriorating audio system and installed a modern replacement speaker within the original housing.
- Upgraded legacy display technology by wiring and installing a backlit, enlarged Retro Pixel IPS LCD panel.
- Troubleshot circuit board failures, restoring non-responsive button contacts using isopropyl alcohol and clean solder joints.
Custom Mold Casting & Tabletop Props
Employed resin casting, silicone mold making, and LED circuitry to create highly detailed scenic props and tabletop accessories.
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- Staff of Ra Headpiece: Formed custom silicone molds to cast transparent ruby resin jewels, achieving high-clarity light refraction.
- "Desert's Kiss" Dice Tower: Split and fused 3D models using sandable plaster, permanently embedding and wiring internal LED lighting arrays.
- Distressed Lantern: Extracted and modified LED diodes to simulate organic candlelight, paired with custom frost-glazing and metallic dry-brushing.
Laser-Engraved Manufacturing
Produced vector graphic designs using Inkscape for precise laser-cutting and engraving operations via a Glowforge system.
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- Transformed raster images into scalable vector graphics (SVG) specifically formatted for machine-readable cutting paths.
- Calibrated laser speed (250-1000) and power parameters (75-100) to optimize engraving depth and prevent scorching on adhesive-backed cork.
- Manufactured batch runs of promotional items (48+ units) with high consistency and rapid turnaround times.
Project Management
Eagle Scout Courtyard Renovation
Directed a large-scale courtyard renovation project at Lake Zurich Middle School South, coordinating logistics and managing volunteer personnel.
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- Recruited and led a team of 62 volunteers to execute the project within scheduled timelines.
- Managed the assembly of site furniture (four benches, three 7-foot signposts) and the distribution of over 23 yards of landscaping mulch.
- Communicated project proposals, scopes, and updates effectively with school administration and non-profit stakeholders.
