Rehan Khan

Rose-Hulman Institute of Technology · Terre Haute, IN

Relevant coursework: Introduction to Design, Graphical Communications, Statics & Mechanics of Materials I & II, Conservation & Accounting Principles, Electrical Systems & Lab, Computer Programming

Structural Lead

• Current structural development and manufacturing lead, designing airframe components in Fusion 360 and overseeing their fabrication.
• Manage the Fusion 360 hub for 25+ members on one of Rose’s fastest-growing teams and train new members in CAD for future airframes.
• Fully designed the frame and mechanical layout of a prototype drone and helped build it from on-hand supplies, giving the software team an early test platform.
• Simultaneously coordinated early VTOL concept designs that evolved into the team’s current aircraft.

EM 103 Introduction to Design, team of 4

• Co-designed a folding xylophone in a 3D-printed, carbon-fiber clamshell with an integrated handle and tablet stand that closes to 11 × 11 × 3 in and weighs under 5 lb.
• Sized 12 brass bars with beam vibration theory and hand-tuned every note to within ±10 cents.

• Filtered a grayscale image into five tonal SVG layers and laser-cut them as cardboard stencils.
• Airbrushed the layered stencils onto a wall to produce a realistic mural in under 5 hours.

• Designed and fabricated a CNC-milled aluminum unibody keyboard case and aluminum keycaps.
• Engineered a custom PCB for DFM, including schematic design, key matrix layout, and firmware.

• Redesigned the PCB shape and 4-layer layout in KiCad to fit the OEM Logitech G Pro X Superlight shell, adding contactless magnetic buttons and haptic feedback for improved performance and feel.
• Hand-assembling the board using stenciled solder paste and hotplate reflow of QFN and 0402 parts.
• Refined the design with professionals, resolving antenna, power, and clearance issues.

Team Leader, Lead Engineer

• Led team to three straight state titles; designed three design-award-winning robots, two of which also won innovation awards.
• Planned in-school robotics events that grew the team by seven members in a single semester.

Assistant

• Wrote equipment safety documentation and mentored underclassmen on shop tools and projects.