Featured Projects

Project Overview

Timeline: August 2025 – Present
Role: Design + Fabrication Lead
Location: George Mason University

Problem

George Mason University needed a 6'×6' interactive display featuring a topographical terrain map of Northern Virginia for their Consumer Electronics Show (CES) booth.

Design & Fabrication

Terrain Base: Executed precision CNC routing of the terrain base and managed the 3D printing and detailing of 40+ scaled tech company building models.

Custom Elements: Managed integration of custom model train tracks and scenic elements to showcase GMU as the central tech innovation hub.

Technical Challenges

• Large-format CNC machining requiring precise material handling
• Managing 40+ individual 3D printed building models
• Integration of multiple fabrication techniques
• Coordinating logistics and timeline for trade show deadline

What I Learned

Project management at scale, coordinating multiple fabrication processes, and working under trade show deadlines.

GitHub: github.com/TanKgVn/TechtopiaMap-CES-GMU

Project Overview

Role: Developer
Location: Mason Innovation Exchange (MIX), George Mason University

Problem

CNC operators at the MIX Fabrication Lab needed a quick, reliable way to calculate optimal feeds and speeds for wood CNC machining operations across different wood species and tool configurations.

Solution

Built a custom web-based calculator that computes RPM, feed rate, chip load, and material removal rate based on material type, tool diameter, number of flutes, and depth of cut. Designed specifically for the CNC routers available at the MIX.

Key Features

• Support for multiple wood species with pre-configured material properties
• Calculations for RPM, feed rate, chip load, and plunge rate
• Tool library with common endmill configurations
• Clean, intuitive web interface for quick shop-floor use

What I Learned

Deepened understanding of CNC machining parameters and their relationships, and how to translate manufacturing engineering knowledge into a practical software tool.

GitHub: github.com/TanKgVn/cnc-feedsnspeed-calculator

Project Overview

Role: Developer
Location: Mason Innovation Exchange (MIX), George Mason University

Problem

Metal CNC machining requires more precise parameter calculations than wood due to harder materials, higher cutting forces, and greater risk of tool breakage. The MIX needed a dedicated calculator for metal operations.

Solution

Developed a custom metal CNC feeds and speed calculator tailored to the machines and tooling available at the MIX. Supports various metal alloys including aluminum, mild steel, stainless steel, and brass with appropriate surface speed recommendations.

Key Features

• Material database with surface feet per minute (SFM) values for common metals
• Calculations for spindle speed, feed rate, chip load, and material removal rate
• Coolant and tooling recommendations per material
• Safety guidelines for metal machining operations

What I Learned

Advanced understanding of metal cutting theory, tool wear mechanics, and the critical differences between machining parameters for wood vs. metal — directly applying mechanical engineering principles from my degree.

GitHub: github.com/TanKgVn/Metal-CNC-Feeds-and-Speed-Calculator

Problem

Wanted to create a low-power weather display using e-paper technology with ESP32 microcontroller.

Constraints

V2 Waveshare display had persistent ghosting issues not documented in standard guides.

Solution

Developed custom code in VS Code with PlatformIO, implemented hardware-specific initialization sequences to eliminate ghosting on V2 displays.

Results

Fully functional weather display with crisp, ghost-free updates. Documented V2-specific fixes for the community.

What I Learned

Hardware version differences matter. Importance of thorough documentation and systematic debugging.

Project Overview

Custom-designed bottle opener showcasing precision CNC woodworking with decorative inlay techniques.

Fabrication Process

Material Selection: Cherry wood for main body with walnut inlay for visual contrast and durability.

CNC Machining: Precise toolpath planning for clean edges and smooth surfaces with careful attention to feeds and speeds.

Inlay Technique: Routed pockets for walnut inlay pieces, ensuring tight fit and flush final surface.

Technical Challenges

• Optimizing toolpaths for hardwood without burning or tearout
• Achieving precise inlay pocket depths
• Selecting appropriate finish for durability and food safety

What I Learned

Hands-on experience with hardwood CNC parameters, inlay techniques, and finishing methods.

Project Overview

Timeline: April 2024 – May 2025 (Capstone Project)
Team: International Collaboration | George Mason University

Demo Video

Design Goal

Collaborated with an international team to design a soft gripper for gentle handling in medical and agricultural applications.

Development Process

Pneumatic System: Developed and tested a pneumatic actuation soft gripper using 3D-printed molds and silicone casting.

Electronics Integration: Designed and integrated a compact electronics case onto a mobile robotic platform using VEX.

What I Learned

Advanced manufacturing techniques in silicone casting, pneumatic system design, and international team collaboration.

🏆 Award

3rd Place - GMU Hackfax 2025 "A Better World" Theme

Project Overview

Compact, non-invasive wildlife tracking device using ESP32 with accelerometer, pulse sensor, and GPS module. Monitors movement, location, and heart rate in real time.

Technical Implementation

• ESP32 microcontroller for data collection and wireless transmission
• GY-521 accelerometer/gyroscope for movement tracking
• Pulse sensor for heart rate and stress monitoring
• GPS module for real-time location tracking
• Compact design fitting in 100mm x 70mm enclosure

Accomplishments

• Real-time GPS tracking for movement patterns
• Heartbeat monitoring for stress detection
• 3D-printed, animal-mountable case
• Wireless data transmission via Oracle Cloud

GitHub: github.com/2186/rosie-tracker

🏆 Award

Winner - GMU HackOverflow 2025 Beginner's Track

Overview

Portable, battery-friendly device based on Arduino Nano ESP32 for real-time monitoring of environmental conditions and health metrics.

Key Features

• ⚙️ Multi-Sensor Integration: Water level, light, humidity, temperature, GPS, heartbeat
• 🌐 Live Dashboard: HTTP server delivers live data to any browser
• 📶 SoftAP Mode: ESP32 hosts its own network
• 🖥️ OLED Display: Real-time visual feedback

Future Work

• Cloud Integration with Firebase or AWS
• Solar charging for continuous field operation
• Machine learning for anomaly detection

GitHub: github.com/tchau23/Green-Heart