# Chris Foster > Sr. Mechanical Engineer | R&D Leader | Medical Devices and Product Development | Available for Consulting & Full-Time Roles Location: San Francisco, California, United States Profile: https://flows.cv/chrisfoster1 I’m a hands-on Mechanical Engineer and R&D leader with over 15 years of experience developing Class I–III medical devices and wearable technologies—taking products from early concept through commercialization. I specialize in: • Mechanical architecture & complex assemblies • V&V strategy, DFM/DFA, root cause analysis • Design controls, risk management, and clinical readiness • Injection molded, machined, and sheet metal components (SolidWorks + PDM/FEA) I've led cross-functional teams and collaborated with vendors and manufacturers to bring novel devices to life, including temperature-controlled RF systems, catheters, and connected wearables. 🔍 Currently open to full-time opportunities and select consulting or contract roles. Let’s connect if you're looking for someone to jump in quickly and deliver high-impact results in your medtech program. ## Work Experience ### Staff R&D Engineer, Instruments @ Calyxo, Inc. Jan 2025 – Present | Pleasanton, California, United States ### Independent Consultant / Contract Mechanical Engineer @ Self-Employed / Freelance Jan 2025 – Jan 2025 | San Francisco Bay Area • Supported early-stage medtech startups in product development, testing, and design transfer. • Led verification and validation (V&V) efforts for a next-gen RF ablation system with Aerin Medical. • Conducted comprehensive intellectual property research for Freedom to Operate. ### R&D Manager @ Aerin Medical Jan 2023 – Jan 2025 | Mountain View, California, United States • Spearheaded the development and commercialization of a temperature-controlled RF handpiece, overseeing design, prototyping, and regulatory compliance. • Enhanced product performance through strategic design improvements, resulting in a significant reduction of field failures. • Successfully managed the transfer of manufacturing to an overseas contract manufacturer, ensuring timely delivery and supporting product launch. ### Sr. Mechanical Engineer @ CreateMe Jan 2022 – Jan 2023 | San Francisco Bay Area • Led the design and development of an IoT-connected infrared heating system, enhancing the direct-to-graphics printing process. • Mentored junior engineers, fostering a collaborative environment and contributing to multiple patents. • Designed and integrated sheet metal enclosures and electrical circuit diagrams, optimizing system performance and reliability. ### Product Development Manager @ NewDealDesign Jan 2020 – Jan 2022 | San Francisco, California, United States • Led the mechanical development of an IoT wearable GPS tracker with biometric sensors, overseeing product definition, product architecture, and prototyping. • Collaborated with industrial design, UX, electrical engineering and RF design firm teams to integrate removable bands, sensors, antennas, and battery solutions. • Contributed to intellectual property development, ensuring a competitive edge in the market. ### R&D Manager @ BioTrace Medical Inc. Jan 2019 – Jan 2020 | Menlo Park, CA • Spearheaded a next-gen catheter project from concept to commercialization, ensuring successful 510(k) special submission. • Coordinated cross-functional teams in engineering, quality, manufacturing, and regulatory. • Implemented DFx principles, achieving a 60% reduction in COGS and enhancing product manufacturability. • Prototyped advanced catheter components to improve product performance. ### Sr. R&D Engineer @ Pulse Biosciences, Inc. Jan 2017 – Jan 2019 | San Francisco Bay Area • Led the design and development of innovative disposable treatment tips for a PFA system for a novel treatment of skin lesions. • Collaborated with cross-functional teams, including electrical, clinical, and marketing, to ensure product alignment with market needs. • Managed vendor selection and streamlined the transition from prototyping to early production. ### Staff R&D Engineer @ Invuity Inc. Jan 2012 – Jan 2017 | San Francisco, CA • Contributed to the development of an electrosurgical device, preparing key deliverables for 510(k) submission. • Led cross-functional teams to commercialize multiple families of soft tissue retractors, managing comprehensive design history files. • Collaborated with physicians and design firms to optimize user specifications for medical devices. • Mentored team members and trained overseas manufacturers, ensuring high-quality production standards. ### R&D Engineer @ Minerva Surgical, Inc. Jan 2009 – Jan 2012 | San Francisco Bay Area • Supported the development of a Class III RF-ablation handpiece and pulse generator for women's healthcare. • Created mechanical designs, technical drawings, and manufacturing process instructions (MPIs). • Developed comprehensive test protocols and reports to ensure product compliance and performance. • Collaborated closely with cross-functional teams throughout the clinical trial process, enhancing product efficacy. ### Energy Engineer @ VaCom Technologies Jan 2008 – Jan 2009 | San Luis Obispo, California, United States • Analyzed and modeled refrigeration and HVAC systems to optimize building energy consumption. • Authored comprehensive technical reports for building owners and utility representatives, promoting energy efficiency initiatives. • Collaborated with cross-functional teams to implement energy-saving solutions, resulting in significant cost reductions for clients. ### Product Design, Portables Group Co-op @ APPLE INC. Jan 2007 – Jan 2007 | San Francisco Bay Area • Contributed to continuation engineering efforts to enhance product quality through comprehensive field failure analysis. • Conducted in-depth material studies for plastic and metal enclosures, ensuring optimal performance and durability. • Evaluated and tested Engineering Validation Test (EVT) and Design Validation Test (DVT) units, providing critical feedback for product improvements. ### New Product Development Intern @ Lam Research Jan 2006 – Jan 2006 | San Francisco Bay Area • Conducted in-depth analysis and reporting of critical sensor data for a vacuum test stand, facilitating communication between hardware and firmware teams. • Recognized with the Above and Beyond Award for exceptional contributions to New Product Development. ## Education ### Master's of Science in Mechanical Engineering California Polytechnic State University-San Luis Obispo ### Bachelor's of Science in Mechanical Engineering California Polytechnic State University ## Contact & Social - LinkedIn: https://linkedin.com/in/chris-j-foster-me --- Source: https://flows.cv/chrisfoster1 JSON Resume: https://flows.cv/chrisfoster1/resume.json Last updated: 2026-04-13