Project 02 of 04

Culligan International

Design internship with four workstreams: a float redesign for a water softener valve, a booster pump kit, a field-training prototype, and drawings for 5 commercial water softeners.

Role: Mechanical Engineering Design Intern
Dates: May – Aug 2026
Location: Rosemont, IL

Reassembly cost removedFloat redesign: $15K/yr
Water pressure increaseBooster pump kit: 150%
Funding securedField-training prototype: $75K
Commercial softeners3D models and drawings: 5

ConfidentialThis work is confidential. The images here were approved for public release, and some details are left out.

Three panels of the injection-molded float: a photo of the black molded part, a gray 3D model, and the same model shaded green and red for comparison — Water softener valve float
I 3D modeled this injection-molded float and drafted its GD&T drawings. The redesign removes about $15,000 per year in reassembly costs caused by a broken part.

Static structural FEA plot of the acrylic mounting bracket with a von Mises stress color scale, boundary conditions and a results summary — Acrylic bracket FEA
Static structural analysis of an acrylic mounting bracket: maximum von Mises stress of 2,217 psi and a factor of safety of 2.94.

Open hard-shell case with perforated aluminum mounting panels in the lid and base — Field-training prototype
I fabricated this portable training prototype and sourced its parts. It secured $75,000 in funding.

Two drawing sheets for commercial water softener systems, with orthographic views, a data table and notes — Commercial softener drawings
I made 3D models and technical drawings for 5 commercial water softeners.

Not pictured

Booster pump kit for a commercial hydraulic valve: water pressure up 150%

Water softener valve float

Acrylic bracket FEA

Field-training prototype

Commercial softener drawings