Brian Sahagian

Mechanical Engineering @
Boston University

I'm a senior Mechanical Engineering student excited by hands-on prototyping, robotic systems, and hardware-software integration. With a strong foundation in design and manufacturing, I build efficient mechanical systems enhanced by smart programming that drive to solve real-world problems. Welcome to my portfolio showcasing my skills and projects.

Brian Sahagian - Mechanical Engineering Student

My Projects

A collection of my engineering projects and achievements

Class Projects

Water Quality Monitoring Buoy

Senior thesis — a sensor-equipped mooring buoy that continuously monitors water quality and predicts cyanobacteria and E. coli levels. Led full mechanical design including CAD, thermoforming, CNC machining, and waterproofing.

SolidWorks CAD Thermoforming CNC Milling System Integration

PID Controlled Transport Cart

Autonomous cart using a PID control algorithm implemented in Arduino to transport a vertical aluminum rod at maximum speed while maintaining stability, validated with SolidWorks motion analysis.

PID Control Arduino SolidWorks Motion Motor Control

Linear Stage Painter Plotter

2.5 degree of freedom robotic system capable of automatically painting and drawing images on canvas using MATLAB, G-code processing, and Arduino control systems.

MATLAB Arduino Control G-Code Processing Robotics

Encrypted Laser Communication System

Wireless optical communication device using Arduino microcontrollers for encoding and decoding binary sequences, designed for automated machine control applications.

Arduino Programming C++ Digital Communication Systems Design

Mechanical Oscillator Analysis

Advanced data acquisition system using linear potentiometers and LabVIEW to characterize frequency response of nonlinear mechanical systems with comprehensive uncertainty analysis.

LabVIEW MATLAB Data Acquisition System Dynamics
Machine Shop Projects

Precision CNC Lathe

Precision CNC lathe operation to manufacture chess pawns from aluminum stock, focusing on achieving superior surface finish and dimensional accuracy through CAM programming.

ProtoTrak CNC Fusion CAM Machine Calibration Precision Machining

3-Axis CNC Milling

CAD-to-CAM workflow on HAAS CNC mills using HSMWorks, producing custom HDPE coaster sets through toolpath optimization, workholding, and precision finishing.

HAAS CNC HSMWorks Fusion CAM Toolpath Generation

Custom Thermoformed Storage Bins

Designed and manufactured custom storage solutions for machine shop organization using vacuum thermoforming and 3D printing integration.

Vacuum Thermoforming 3D Printing Product Design Manufacturing

Machine Maintenance & Repair

Comprehensive maintenance program including horizontal bandsaw care and cold saw pump replacement, ensuring optimal equipment performance and safety.

Preventive Maintenance Mechanical Repair Troubleshooting Equipment Care
Personal Projects

Honda Motorcycle Rebuilds

Complete restoration of vintage Honda motorcycles including full engine rebuilds, valve replacement, and component restoration on 1980 CM200T and 1969 CB350 models.

Engine Rebuilding Mechanical Diagnosis Restoration Precision Assembly

Fixed Gear Bicycle Build

Complete conversion of vintage Panasonic road bike to fixed-gear configuration with custom component selection and frame restoration.

Bicycle Mechanics Component Sourcing Assembly Maintenance

Jeep Wrangler Maintenance

Comprehensive automotive maintenance and repair on 2001 Jeep Wrangler focusing on brake systems and preventive care.

Automotive Repair Brake Systems Troubleshooting Preventive Maintenance

DSLR Film Scanner Build

Custom 35mm film digitization rig built with 8020 aluminum extrusion, a macro lens, and a backlit light tray for in-house negative scanning.

8020 Fabrication Optical Alignment Macro Photography Post-Processing

Work Experience

Professional experience and key contributions

HVAC Engineering Intern

Jaros Baum & Bolles Summer 2025

Supported team of HVAC Engineers outfitting new and renovated buildings with to-code HVAC equipment. Worked on high-profile projects including Northeast corridor such as offices, data centers, and laboratories.

  • Performed heating and cooling load calculations using Trane TRACE software and sized HVAC equipment accordingly
  • Reviewed equipment submittals and checked code requirements (ASHRAE, SMACNA) to accept/deny contractor proposals
  • Drafted and revised HVAC systems in Revit, maintaining company and industry standards
  • Completed thermal comfort study for Bain Capital's John Hancock Tower (200 Clarendon St) renovation in Boston
  • Designed HVAC systems for CV Properties 200 Dyer Street Apartment building in Providence, RI

Machine Shop Student Advisor

Boston University Engineering Product Innovation Center Fall 2024 - Present

Oversee BU's Machine Shop floor and product design center, supervising students and maintaining advanced manufacturing equipment. BU SciShield Lab Safety certified.

  • Supervise machine shop operations and teach students proper use of Haas CNC Mills, Proto-Trak CNC Lathes, and Bridgeport Manual Mills
  • Optimize engineering project designs with machining-conscious and efficiency-driven decisions
  • Enforce strict safety protocols and perform routine maintenance on manufacturing equipment
  • Manage advanced equipment including Bambu 3D printers, FormLabs resin printers, ProtoMAX Waterjet, and Epilog Laser Cutter
  • Personally responsible for upkeep of adopted horizontal bandsaw through Adopt-A-Tool program

Research and Design Mechanical Engineering Intern

Rypos Inc. Summer 2021

Optimized Rypos' Diesel Automotive Particulate filter design through materials research and testing. Developed lab safety protocols and presented findings to engineering team.

  • Tested and selected new concrete-based alternatives for filter adhesive materials
  • Conducted analysis and strength testing of automotive particulate filter components
  • Developed lab safety, precision, and data accumulation skills in industrial research environment
  • Presented weekly progress updates to Rypos' team of engineers, demonstrating public speaking skills
  • Contributed to optimization of diesel automotive particulate filter housing design

Technical Skills

Technologies and tools I work with

CAD & Design Software

SolidWorks
Fusion
Onshape
Revit

Programming & Software

Python
C/C++
MATLAB
Git

Manufacturing & Fabrication

CNC Machining
Rapid Prototyping
3D Printing
GD&T

Beyond Engineering

Biking
Engine Work
Mountain Adventure
Skateboarding
Surfing
Acadia Adventure

Outside the classroom, I'm always exploring passions that fuel creativity and drive innovation, from skateboarding and surfing to cycling, snowboarding and beyond. I have a deep appreciation for analog tech, specifically vintage cameras and old motorcycles. I love working on, repairing, and improving any system I can get my hands on. When I'm not tinkering in my garage or skating with friends, I'm likely outdoors exploring and discovering new places!

Get In Touch