I still remember the thrill when I found this opportunity through my college’s summer internship-for-credit class. Pattern Labs, a startup in Erie, Colorado, aims to revolutionize airport baggage handling with automated shuttles and optimized software. The chance to work with robots and help create something groundbreaking for the airport industry was exactly what I’d been hoping for.

Taking on Pathfinder: Retrofitting for ULDs

My main task was to retrofit the Pathfinder robot to load and unload Unit Load Devices (ULDs)—the containers airlines use for securely transporting luggage and cargo. While ULDs are common in Europe, they’re just catching on in the U.S., so it felt exciting to work on a project with real-world impact. At first, I thought the project would be straightforward, but as I began mapping out design constraints, its complexity grew. One of the biggest challenges was fitting the entire assembly into Pathfinder’s chassis while adhering to a strict height limit, with only 6-10 inches to work with.

Being the sole intern on this project and in the team, I had to rely heavily on my own judgment to turn these loose customer requirements into a functioning prototype. Working with full autonomy was both daunting and empowering, as I navigated design reviews and obstacles like sourcing parts on time, staying within budget, and meeting strict height requirements. I wanted to respect my team’s time, only calling for meetings when I had well-prepared findings and design plans. Each challenge called for patience, deep problem analysis, and breaking the work into manageable sections. I learned to make the most of team feedback and take advantage of their expertise to refine my design.

From Loose Requirements to a Functional Prototype

Bringing this project from rough ideas to a fully assembled prototype in just two months wasn’t easy. Managing multiple part orders, splitting vendors to cut down on shipping costs, and even crafting parts myself kept me constantly on my toes. One workaround I devised was to purchase stock metal locally to make custom parts, sidestepping high shipping costs. When parts didn’t fit perfectly, I tackled the tolerance issues with tools like the angle grinder, embracing the hands-on, iterative nature of the work.

I was also given a side project: building a buffer table to temporarily hold ULDs. While it seemed simple initially, this “metal IKEA bed frame” was surprisingly challenging. Instead of welding, I opted to bolt the table for easier assembly and disassembly, which led to additional challenges in procuring fasteners, submitting fabrication requests, and creating engineering drawings for sheet metal cutting.

Diving into Electronics and Beyond CAD

After completing the project a week ahead of schedule, I was eager to branch out from CAD into the electronics side. I expressed my interest in wiring and soldering to my supervisor, who gladly gave me new tasks, from soldering and PCB manufacturing to creating a schematic for the onboard computer and power system. I completed these tasks quickly and received positive feedback on my attention to detail, which was incredibly rewarding.

First Day Surprises and Startup Culture

Interestingly, my first day at Pattern was unexpected. I arrived expecting to dive straight into mechanical design, only to find it was office cleaning day in preparation for an investor visit. My initial disappointment faded when my supervisor reassured me about the importance of shared responsibility. Seeing him mop the floor himself was a powerful moment. When I offered to take over, he kindly declined, saying he’d find me “a less lousy task.” That was my first glimpse into the hustle culture at startups, where everyone pitches in and no one is above any task. It felt like family, and I loved that about Pattern.

Overall, working with Pattern was a challenging, enriching, and unforgettable experience. I’m so proud of what I achieved in just three months and excited to carry forward everything I’ve learned. From building prototypes to navigating the startup culture, every moment was a learning experience that strengthened my technical skills, problem-solving abilities, and adaptability.