Highlighted Skills

3D Modelling & Additive Manufacturing

Custom Electronics

I create software that bridges the gap between physical hardware and smart automation. Example projects include barcode‑scanning sorters, lightweight time‑clock systems, and AI workflows that move data to the right place automatically. Learn more

I design and 3D‑print custom parts, jigs, mounts, and prototypes that add functionality and simplify workflows. From cloning legacy parts to rapid prototyping, 3D design lets me test ideas before committing to full production. Learn More

I build bespoke devices for monitoring, control, and testing. Projects range from mixer tachometers and portable safety‑sensor testers to production simulators that remove environmental variables and speed up troubleshooting. Learn more

Software & AI Automations

Case Study: 80% More Output with Automated Powder Transfer

When an employer’s production line was slowed by manual handling, dust exposure, and flow issues, I stepped in to design a smarter solution.
The result? A fully enclosed system that streamlined operations, improved safety, and boosted output—without adding complexity.

Pre-solution...

Before the upgrade, the powder transfer process was manual and time-consuming, contributing to bottlenecks across the entire production line:

• A team of five operators was required to keep the line running smoothly.

• To keep powder covered, a large portable strip curtain enclosure was used.

• This structure had to be moved to a full washdown area for cleaning, adding downtime and labor.

• Bridging often disrupted flow, slowing operations and requiring manual clearing.

• The open handling process created airborne dust and cleanup challenges.

• Overall, transfer speed and reliability limited output.

The St.Louis Solution...

The upgraded system replaced manual handling with a fully enclosed, automated transfer solution designed for speed, cleanliness, and reliability:

• A sealed bulk bag unloading system ensures powder is never exposed to the environment.

• An in-hopper agitator prevents bridging before the infeed auger.

• Improved hopper geometry and a larger auger significantly boosted feed rates.

• These changes increased output by 80% and allowed the line to run with one fewer operator.

• No more strip curtain enclosures. No more washdowns.

• Dust is eliminated, and cleaning is simplified.

The result: a safer, faster, and cleaner process with less labor and more output.

Ready to Solve Your Material Handling Challenges?

Whether you're battling dust, downtime, or flow issues, I design smart, custom solutions that make your operation faster, safer, and easier to manage.

LineX PROJECTS

Have a process that’s slowing you down? Let’s build a better one.
Get in touch to turn your bottlenecks into smart, scalable solutions.

When IXS Coatings needed a smarter way to service their polyurea spray systems, I designed and built a fully closed-loop flush station that transformed their maintenance workflow.
By separating the A and B chemical components and implementing a solvent recirculation system, this solution drastically reduced waste, protected sensitive equipment, and cut operator involvement in half. It cleans two machines at once, allows mid-cycle refilling, and maintains a sealed environment — all while improving reliability and reducing downtime.
This system wasn’t just a fix — it became the new standard.

High-Pressure Spray System Flush Station

Automated Spray Simulation for Diagnostics

Manual testing was a bottleneck for IXS Coatings' repair technicians. I built a simulation tool that replicates real-world spray behavior using a custom-programmed single-board computer.
With this system, machines can be thoroughly tested — hands-free — right after repair. It eliminated the need for constant supervision, freed up technician time, and made the diagnostic process more consistent and thorough.
The result: faster turnarounds, better repairs, and a more scalable maintenance operation.

Testimonials

Lane Brown

- Operations Manager

Ryan Anderson

- Maintenance Manager

"Alex St. Louis played a critical role in transforming our operations at Titan Manufacturing. His creative problem-solving, deep technical knowledge, and full ownership of complex projects led to major improvements in efficiency and throughput — including an 80% boost in production capacity. From systems integration to OEE implementation, Alex brought both strategic insight and hands-on leadership that made a lasting impact."

"Alex St. Louis delivered two innovative solutions that improved both the efficiency and reliability of our high-pressure polyurea spray systems. He engineered a closed-loop flush station that drastically reduced solvent waste while simplifying the purging process for multiple machines. In a second project, he developed a simulation system that allowed unsupervised testing and more thorough verification of machine repairs. Both systems freed up technician time and improved our overall workflow — a real step forward for our maintenance operations."

Renee Fox

– Quality Manager

“During Alex’s time with Titan Manufacturing, I consistently saw his ability to approach complex challenges with creativity and precision. He has a unique talent for diagnosing issues that others overlook and implementing solutions that not only resolve the immediate problem but also strengthen our processes long-term. Alex brings an exceptional level of technical expertise to every project—whether it’s troubleshooting equipment, designing custom tools, or integrating systems for efficiency. Just as importantly, he brings professionalism and collaboration to every interaction. His contributions raised the standard of quality in our operations, and I have no doubt he will continue to be an asset wherever he applies his skills.”

Kevin Wise

- Director of Product Development

“Alex played a critical role in commissioning and launching our automated manufacturing department here at IXS Coatings. He not only provided creative solutions to improve start-up efficiency but also led troubleshooting efforts that fine-tuned the control systems driving our production. Alex was instrumental in configuring data protocols to ensure seamless integration with our ERP system, and he became the go-to resource for training operators on these processes. His ability to blend hands-on technical skills with big-picture problem-solving has been invaluable. Beyond his expertise, Alex’s motivation and teamwork have had a lasting impact on our facility’s growth. He is an outstanding asset to any organization.”

Add versatility to your equipment

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Clone OEM parts

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Setup Jigs

Custom adapters enhance functionality and standardize your production workflow.

Whether it’s a legacy part, overpriced, or has long lead times, cloning parts can be a huge win.

Changeovers can be a difficult and time-consuming process. Custom setup jigs can take out the guesswork, speed up the process and free up technical resources.

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Custom tooling

Whether it's a 5s organization project or a tool for automating manual processes, custom tooling can be an output multiplier.

Protect Critical Equipment from Damage

Test Ideas Before You Invest

Mount anything anywhere

From protecting equipment to streamlining production, here’s how custom design and additive manufacturing can transform your operations.

Prevent costly damage with custom covers, caps, and shields that fit perfectly and keep sensitive components safe.

Test ideas, check fit, and validate designs before committing to expensive production runs.

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Install sensors, cameras, or tools exactly where you need them with precision-fit mounting solutions.

How Can 3D Modeling and Additive Manufacturing Transform Your Operations?

Ready to get started?

Contact me to see how custom 3D design and additive manufacturing can solve your toughest challenges.

CONTACT US

If you're interested in hearing more about the way I work, have a business proposal, or are interested in making a purchase, I'd love to hear from you.