Hi, I'm Brian Sahagian

Mechanical Engineer | Software Integration Specialist

I'm a senior Mechanical Engineering student at Boston University with a passion for bridging traditional mechanical systems with cutting-edge software implementation and robotics. Welcome to my portfolio showcasing innovative projects at the intersection of hardware and software.

Brian Sahagian - Mechanical Engineering Student

About Me

Get to know me and my engineering journey

Engineering Through Hands-On Experience

I'm a student of the world who thrives on hands-on work. Whether I'm programming Arduino controllers, machining parts in BU's machine shop, or rebuilding 70's motorcycle engines, I love bringing theoretical concepts to life through practical application. My academic foundation in mechanical systems and materials science comes together best when I'm actually building something.

My primary interest lies in robotics and software-integrated systems—creating intelligent machines that can sense and respond to their environment. Outside of engineering, I'm passionate about photography, skateboarding, snowboarding, surfing, bicycling, and more. These diverse interests keep me creative and often inspire fresh approaches to engineering challenges.

Engine Work

My Projects

A collection of my engineering projects and achievements

Class Projects

Rod Balancing Transport System

Autonomous vehicle system using Arduino control and SolidWorks motion analysis to transport vertical aluminum rods at maximum speed while maintaining stability.

Arduino Programming SolidWorks Motion Motor Control System Dynamics

Monet Machine - Automated Painter

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

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

Precision Gasket Manufacturing

Complete reverse engineering workflow from physical measurement to CNC manufacturing, demonstrating precision measurement and CAD-CAM integration skills.

Precision Measurement SolidWorks CAD HSMWorks CAM Reverse Engineering

Mechanical Oscillator Analysis System

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

CNC Chess Piece Manufacturing

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

HDPE Coaster - CNC Milling

Complete CAD-to-CAM workflow using HAAS CNC mills and HSMWorks, demonstrating advanced toolpath optimization and precision manufacturing.

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

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
HSMWorks
Fusion CAM
Revit

Programming & Software

Arduino
C/C++
MATLAB
Git

Manufacturing & Fabrication

CNC Machining
ProtoTrak & HAAS
3D Printing
Manual Machining

Beyond Engineering

Exploring passions that fuel creativity and drive innovation

Mountain Adventure
Skateboarding
Surfing
Biking

Get In Touch

Let's connect and discuss opportunities

Let's Work Together

I'm always open to discussing new opportunities, collaborations, or just having a conversation about engineering and technology. Feel free to reach out!