Mechanical Engineering · R&D Consulting

Mechanical engineering consulting for robotics, medical devices, and product development.

I help startups and engineering teams develop electromechanical products—from concept and CAD through prototyping, testing, and manufacturing support. Prosthetics and robotics are specialties, not the limit of what I build.

Schedule a consultation Call · 203.809.1485

5+
Years in device R&D

3
Patents

Selected Hardware

A look at the hardware side of the work — the product, the process, and the machines and fixtures behind it.

Completed semi-active ankle prosthesis prototype, second view

CAD render of the semi-active ankle/foot prosthesis

Completed semi-active ankle prosthesis prototype, side view

Cutaway CAD render showing the motor, ball screw, and series spring

GUI for controlling and monitoring the prosthesis

Bench-top test setup with the prosthesis and control electronics

HGN Lab for Bionic Engineering

Semi-Active Ankle Prosthesis

A non-backdrivable brake mechanism allows the prosthesis to switch between active and passive modes—providing assistance during activities like stairs and sit-to-stand while allowing passive operation during walking phases where energy input is unnecessary or battery power is limited.

Ekso Bionics

ISO-13485 Test Machine

Originally designed to test two AFO's. Independent cycle frequency adjustment on each side.

Gait load replication fixture actuating a shoe on a sock-and-last fixture

Ekso Bionics

Gait Load Replication Fixture

Physical build of the patented biomechanical motion device (WO2022086498A1) for replicating human gait loads.

Fillauer Motion Control

Current-Generation Prosthetic Foot

A production foot Fillauer sells today — the platform I'm now building the next generation of, with added functionality.

Ski boot mounted on prosthetic ankle mechanism next to a cosmetic foot

Fillauer Motion Control

A Walk Around the Office

We use ski boots to test the feet we are developing.

Fabrication

CNC Machining

Comfortable programming and running CNC machines to produce precision parts.

BMW K100 motorcycle engine cylinder head

Personal Project

BMW K100 Restoration

Replaced the head gaskets, checked valve clearances, and installed new injectors to get this K100 motorcycle running again. Electrical work to come. I like keeping this type of hands-on work in the mix.

Bending ash chines into shape onto the frames and transom

Fiberglassing the seams with West System epoxy

Completed boat stored on its trailer, holding a canoe

Personal Project

15-Ft Skiff Build

Built a 15-foot skiff from scratch - ash frame, plywood panels, fiberglassed seams.

Résumé

Where the mechanisms have gone.

A working history in prosthetics, orthotics, and robotic assistive hardware — from student research through clinical and commercial devices.

Sam Westgard — Mechanical Engineer

R&D experience across hydraulic and semi-active prosthetics, exoskeletons, and product development — from concept through verified, field-tested hardware.

Download Résumé (PDF)

Credentials