Curriculum vitae

Lucy Chapar (she/her)

Operations & Manufacturing Leader · Hardware Operations Executive

LinkedIn

Summary

Operations and manufacturing leader with over a decade of experience advising organizations on how to design, scale, and stabilize hardware manufacturing systems. Co-founder and operations executive at Opulo (formerly Index Machines), where she advised and led the development of an open-source pick-and-place ecosystem now used worldwide. Brings deep expertise in manufacturing systems architecture, DFM/DFA, NPI, line management, SOP development, supply-chain strategy, and executive decision support. Experienced operating in advisory, interim-leadership, and hands-on implementation roles across startups and established manufacturing environments.

Consulting focus: Manufacturing system design, operational readiness assessments, cost-down and throughput improvement programs, vendor qualification and scale-up strategy, and executive-level operational advising.

Experience

Opulo Inc. (formerly Index Machines Inc.)

  • Co-founded an open-source hardware company and led the design and maturation of its manufacturing systems from early prototype through sustained production.
  • Advised on and implemented supply-chain strategy, vendor qualification frameworks, and production controls to support scale-up.
  • Designed and institutionalized SOPs covering inventory control, purchasing, receiving, QA, and outbound logistics.
  • Led DFM/DFA reviews and development of fixtures and jigs to reduce cycle time, labor cost, and production risk.
  • Established documentation standards and support resources for a global open-source user community.
  • Partnered with leadership on product strategy, pricing models, and long-term roadmap decisions across hardware, feeders, and tooling.

HackPGH (501c3 Nonprofit)

  • Served on the board of a member-run hackerspace supporting hundreds of makers and technologists.
  • Contributed to organizational governance, legal review, facilities oversight, and long-term strategic planning.
  • Advocated for transparent financial controls, clear board process, and member-driven decision-making.

Markforged

  • Supported production operations for composite and metal additive manufacturing systems.
  • Assisted with process documentation, yield tracking, and cross-functional issue resolution across engineering and manufacturing.

Formlabs

  • Focused on line management, root-cause analysis, DFM/DFA, SOP development, and day-to-day manufacturing firefighting.
  • Spent approximately 25% of the year in Shenzhen, China supporting NPI efforts and contract-manufacturer line bring-up.
  • Managed laser module manufacturing programs in close collaboration with optics and electrical engineering teams.
  • Designed calibration fixtures and production equipment for next-generation products.

CNC Software, Inc. (Mastercam)

  • Authored technical documentation and multimedia content for user-facing Mastercam features.
  • Served as an internal consultant on additive manufacturing workflows and tooling.
  • Project-managed the “What's New” video series and supported localization of multimedia content.
  • Collaborated with QA through structured bug testing and feedback loops.

Brandeis University

  • Supported faculty research, including Nobel Prize winning labs, through the design and fabrication of custom fixtures and experimental apparatuses.
  • Developed desktop research platforms and automation tools for laboratory use.
  • Taught CAD and 3D printing to K-12, undergraduate, and graduate students.

Education

Bachelor of Arts

Major: Digital Media Design (Concentration in 3D Visualization)

Minor

Management for Engineering Manufacturing (Concentration in Operations Principles of Information Management)

Selected projects & leadership

UConn 3D Printing Club (3DPC) — Founder & Chief Operations Officer

  • Founded and operated a student-run makerspace with over 300 members. Raised more than $100,000 in funding and sponsorships.
  • Recipient of Editor's Choice and Best in Education awards at Maker Faire 2016.

Open-Source Hardware & Automation Projects

  • Led and contributed to CNC systems, motion controllers, and educational automation tools, with an emphasis on accessibility, documentation, and reproducibility.

Skills

  • Manufacturing Engineering & Operations
  • Management Consulting
  • Startup Advising
  • DFM / DFA / RCA
  • New Product Introduction (NPI)
  • SOP & Documentation Systems
  • Supply Chain & Vendor Management
  • Contract Negotiation
  • Fixture, Jig, and Test Equipment Design
  • Open-Source Hardware & Community Building
  • CAD, CAM, and Digital Fabrication

Affiliations

  • Open Source Hardware Association (Contributor)
  • Maker & Hackerspace Community Organizer

Representative consulting engagements

Groucho Fractal

  • Provided management and manufacturing consulting services to a parent company supporting open hardware and educational technology initiatives.
  • Advised on manufacturability and production readiness across early-stage hardware concepts, including DFM/DFA, materials selection, and process trade-offs.
  • Designed manufacturing workflows, fixtures, and test approaches to support small-batch production, demonstrations, and educational use.
  • Served as a long-term consulting partner to leadership, advising on hardware architecture, cost structure, execution risk, and scale-up strategy.