Sasha Yakovlev

Copenhagen, Denmark | LinkedIn

I turn messy hardware into stable, shippable products — fast, clean, compliant.

I’m an independent engineer and inventor. I design mechanisms and 3D-printed tooling, integrate and validate processes, and take systems from lab to high-volume production. My edge: I’m a printing-systems specialist across modalities — inkjet, screen/stencil, photolithography, PCB manufacturing (paste/stencils), photographic printing, and 3D printing — spanning chemistry, mechanics, and control.

Why people bring me in

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Highlights

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Unique capability — Printing systems (end-to-end)

Result: engineered windows, reliable registration, clean adhesion/cure, inline checks that catch the right things.

Selected stories (from new to repeatable to scalable)

Zero to working prototype — nothing existed yesterday.
I clarified constraints, shaped two concept options, built a quick CAD, printed/assembled the first unit, and wrote a simple test plan.
Outcome: a real, testable prototype (not a render), faster decisions, clear path to NPI.

Prototype that refused to become a product — it worked with “hero” operators and died with the real crew.
I set the process architecture, defined split plans, built a validation pack (installation/operational/performance), and ran a golden build with acceptance.
Outcome: stable ramp with regular operators, fewer redesign loops, earlier first revenue.

Printed features that wouldn’t behave — bridges, voids, and opens across a stencil/screen print step.
I re-designed apertures and step-downs, tuned paste rheology and squeegee dynamics, set snap-off and wipe cadence, and aligned reflow profiles with print limits.
Outcome: first-pass yield up; bridges/opens down; a stable print window documented for operators and suppliers.

Yield on the edge — shipments were slipping; AOI called false rejects; rework piled up.
I mapped the two biggest defect modes, ran a focused DOE, locked the window, and rewrote run-cards and operator checklists.
Outcome: +14% yield in six weeks, −40% escapes, predictable output.

Tooling that pays for itself — assembly and inspection were slow and noisy.
I delivered three fixtures with usage SOPs, acceptance criteria, and a spares kit; integrated quick checks into the line.
Outcome: minutes → seconds on critical steps; cleaner data; escapes down.

Transfer that wouldn’t transfer — every site did it “their way,” and the calendar kept burning.
I produced the documentation pack (run-cards, SOPs, control plan), set maturity gates, trained operators, and closed first-article sign-off.
Outcome: clean hand-off, consistent behavior across sites, fewer back-and-forths.

Printed & flexible electronics, without the mess — learning cycles were too long and measurements drifted.
I produced a functional batch, set up rapid/inline checks, and defined acceptance metrics with simple charts the team actually used.
Outcome: quicker learning and a smooth hand-off to pilot.

From idea to funded — strong concept, weak narrative.
I aligned the call, shaped work-packages and budget logic, added impact metrics, and built a Q&A deck; coached the presentation.
Outcome: higher review scores, funding secured, confident defense to stakeholders.

How I help (prioritized)

  1. Zero-to-first prototype (concept → build → test)
    You get: clarified requirements, concept options, quick CAD, a working prototype, a test plan, and a short report with next steps.
    Result: a real, testable unit; faster decisions; clear path to pilot/NPI.
  2. NPI that survives production (lab → line)
    You get: process architecture, split plan, validation pack (IQ/OQ/PQ), golden build & acceptance.
    Result: predictable ramp; fewer redesign loops; earlier revenue.
  3. Cross-modal printing system tune-up
    You get: a window for your print (ink/paste/geometry), a registration plan, acceptance metrics, and operator checklists.
    Result: repeatable prints, clean adhesion/cure, fewer defects carried downstream.
  4. Stop-the-bleed yield fix
    You get: Pareto, control plan with limits, updated run-cards, operator checklist.
    Result: double-digit yield lift; fewer escapes; firefighting stops.
  5. Devices & mechanisms (DfAM)
    You get: CAD with tolerances & inserts, orientation spec, serviceability notes, BOM + drawings, one prototype.
    Result: first-time assembly; reduced rework; faster iteration.
  6. Tooling that pays for itself (fixtures / jigs / test rigs)
    You get: 1–3 fixtures/rigs, usage SOP, acceptance criteria, spares list.
    Result: minutes → seconds; cleaner data; fewer escapes.
  7. Grants, proposals & defense
    You get: call alignment, work-packages, budget & justification, impact metrics, Q&A deck, pitch rehearsal.
    Result: higher win rate; smoother reviews; confident board/customer presentations.
  8. Supplier / OSAT transfer that holds
    You get: documentation pack, maturity gates, training, first-article sign-off.
    Result: clean hand-off; stable output — the fastest path to scale.

Work history — last 15 years

Full timeline on LinkedIn

  1. Senior Process Engineer — Demant · Copenhagen · 2022–2025
  2. Research Fellow — Fraunhofer EMFT · Munich · 2019–2022
  3. R&D Engineer — IsItFresh · Aachen · 2017–2019
  4. Lead Researcher — ITMO University · St. Petersburg · 2015–2017
  5. Researcher — Institute of Silicate Chemistry, RAS · St. Petersburg · 2012–2015
  6. Research Engineer — RUSAL · Various sites · 2010–2011

Publications & patents (highlights)

Ready to move?

If you need a prototype from zero, a process that survives production, or a yield fix that sticks — I’m your person.

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