SUMMARY:

• 25+ years engineering process & technology expertise as a Design Engineer, Lead Designer, Senior Design Principal, and Engineer Systems Architect 5, Structures, Electro - Mech. Integ.
• Siemens NX thru NX11, 25,000 hrs. Confidential ’s UG over 30,000 Hours Currently using NX11 and Team Center Smaragh Configuration Management Tools.
• Provided fuel systems, structures, tooling, integration design expertise for new wet wing development projects at Confidential, Melbourne Florida.
• Modelled full size wing tanks & perimeter structures for a complete fuel test simulation.
• An actual center-wing structure was fully modified to new specifications as required for the new design.
• Confidential fuel systems IPT team.
• Electronics integration.
• Confidential, checking duties for final Prime Structure configuration, and was designer of custom one-off optical tooling, laser optical test layouts and designed 15-20 ton support structures used for vibratory stress testing. And implemented vibration isolation units.
• Lead Structural IPT for mainframe structure designs and entire systems integration. Tooling oversight at vendor.
• Thermal Heating and cooling system designs, IPT lead for Confidential cooling systems evaluated for efficiency and abilities.
• Oversaw testing with hundreds of thermal couples for input and output temperature deltas. Streamlined drive systems and thermal systems for huge service, downtime and functional improvements.
• Senior Design Principal, Confidential and as a Manufacturing Engineering production specialist. Liaison specialist for the AH1Z Cobra and UH1Y Huey early low production build team, Created V-22 Osprey Tilt rotor gearbox models with port and starboard configurations, Mid-Wing Gearbox and Tilt Rotor gearbox. Primary Structure modifications on H1’s. Gearboxes re-created with full cast in tubing designs.
• Confidential Oxy-Systems Confidential 747-8 trunk lines and 787 self-contained units. Remote fill option for fire systems Liaison team for structural changes with oxygen systems.
• Structures team Confidential, Airbus A300/600 passenger to freighter conversion

SKILLS:

• Siemens NX thru NX11, 25,000 hrs.
• Confidential s UG V3 through V18 over 30,000 Hours
• Catia V5 3500+ hrs. & Enovia, Windchill, Smaragh
• Printed Tools
• PDM Team Center 9.0, SAP
• TCE, One Vault, ISE
• Project Database Management (PDM), Configuration Management
• Structures Primary and Secondary
• Root cause Analysis FEA Consultation
• DFM DFA, American for Poka - Yoke
• Exact Constraint
• Complex Structures, Weldments, Castings
• Turbomachinery
• Green Belt training
• Parametric Modelling MBD, and Printed tools
• Optical Layouts and fixture Designs
• Tool Design, Fixturing
• Master Model (Assemblies and Components)
• Mil - Specs. And Standard Practices
• Shipside GSE, 787-1
• GD&T Geometric Dimensioning & Tolerancing
• ASME Y14.5M-1994/ASME Y14.41-2003
• Fixturing, Tools/Dies Electrical Harnessing, Integration
• AWS American Welding Society standards
• Product Definition / Model Based Design & Definition, Technical Studies
• IPT team, Lifecycle Analysis (LCA)
• Green-Belt training
• Lean and Six-Sigma training
• Weight Management
• ETAC, PSDS, Spatial Integration
• Thermal Dynamics, Confidential designs
• Rapid Prototyping, Stereo lithography
• ISO 9001
• C&E systems analysis
• Negotiation of Design Variables

EXPERIENCE:

Confidential, Birmingham, AL

Design Engineer

Responsibilities:

• Configuration Management. Printed Tooling Developed. NX 11 Final Product delivery layouts and integration.
• Using Engineering Client/Smaragh release system to integrate Catia V5, NX and Solidworks files.
• Tooling Designs to aid in assembly procedures.
• White Body Structures.
• Structural tuning for perfection in assembly.

Confidential, Melbourne, FL, & Chicago IL.

Systems Architect

Responsibilities:

• Created comparison CAD layouts of the entire Center Wing existing fuel system tubing, Aerial re-fueling system, and future extended capacity systems and the impacts and modifications to all wet wing structures.
• Created PPT documentation of modification coordinates, materials and thicknesses of each structural change.
• This was a SOW for all structural mods to existing aircraft structure including capping off previous iterations. RFP begun with visually captured PPT docs and CAD models made available to vendors.
• Developed cross over fuel paths for dry bay at mid-wing. Constant evolution as rib structure stiffening and fasteners moving changed clearance requirements. Team IPT effort to make everything work. NX8.5 Proposals created for alleviating design clashes.
• High End Military RF mechanical electronic packaging design, integration, and release.

Confidential, Dallas, TX

CAD Engineer

Responsibilities:

• Tooling designs for DOD high volume 50 ton ordnance presses. Modified full automation bullet feeder designs in NX9 Created proposals to implement vendor supplied support equipment Job became short term because a family emergency could not be accommodated.
• NX9 Refresher design course taken at Confidential ’s Facility in Dallas

Confidential, Rochester, NY

Structural Designer

Responsibilities:

• Structural tooling redesign of an X-ray Equipment mobile system for an R&D project of a new scanner.
• Combined parts for function, simplified for service and welding procedure in NX8.5 Exact-constraint applied in design for structural integrity.
• FEA run with zero issues.
• SOW developed for structural changes including vendor early involvement and their manufacturing preferences made it clearly a big time saver for build process.

Confidential, Ft Worth, TX

Senior Design Principal

Responsibilities:

• Developed complex surface models in NX6 from lofting for machining titanium V22 wing skins.
• Evolved staging SOW’s for machine centers to speed processes.
• Adapted Composite build processes for rotor blades per rotor Fellow instruction.
• Created negative or open area models for issues surrounding oil flow problems in a new vendor supplied casting for a dual input turbomachinery gearbox.
• Vendor deviations in casting coring discovered and SOW solutions suggested and implemented. NX6
• Numerous DCN and ECO packages checked and created solving material and Mil-spec evolution and discrepancies. GD&T checked for consistency.
• Airframe Structures design updates and problem resolutions on H-1. Rotors/Drives UH-1Y & AH-1Z Rotor and Drives integration assignments writing ECO’s and creating NX6 models for improving manufacturing processes for various models of H1 and V22 aircraft.
• Checker for ECO's written by sub-contractors. Helped develop a SOW checklist guideline for these engineers to aid speed of ECO release.
• Helped resolve issues surrounding oil flow problems in a new vendor supplied casting for dual input turbomachinery. RFP’s given to several vendors supplying large castings to evolve a better coring location system.
• Created numerous Power Point presentations showing SOW optional designs for Military consideration and cost analysis. Investigated the history and development of build processes for building better drives and composite build operations for optimal blade build.

Confidential, Everett, WA

Integration Designer

Responsibilities:

• Designed tubing trunk lines and routing pathways through entire fuselage structure along with tank mounting and regulator systems.
• Represented Oxy systems in twice weekly IPT meetings for communication and collaboration with Electrical Systems (Hi and Low Voltage), Structures, Confidential and Flight controls.
• Resolved oxygen clearance issues with plenum and duct and harness route modifications.
• Released EPIC CAD data into the system for IVT fly-through. Catia V5
• Sow created for entire new trunk line deviations from existing system.
• Proposal for a new Remote Fill Option for Oxygen on the 747-8 Freighter.
• On the 787 Was on the Composite Fastener Standards Substitution Team.
• Fuselage integration Liaison tasks involved with A/P 1 and the Static Test A/P.
• Resolved Structural issues at Fuselage join and Wing to Body join. EE-Bay integration Support using Catia V5 and Enovia Verified the fit, form and function of 3D models and assemblies for structural and mechanical designs.
• Worked with project engineers and electrical engineers to resolve design problems. Designed and tested prototypes of new and existing designs.
• Verified manufacturability and structural acceptability of designs
• Provided senior input to junior designers and reviewed and checked work for quality and accuracy

Confidential, Everett, WA

Senior Mechanical Designer

Responsibilities:

• Confidential 787 Overhead Interior storage modules designed integrated and released Modular passenger Confidential Oxygen Systems design Injection molded parts for universal bottle nesting. NX6
• Multiple releases of varying overhead storage units per customer changes in scope
• Confidential passenger thermal management plenum nozzle designs for intuitive ease of use, and lighting switch designs.

Confidential, Everett, WA

Senior Mechanical Designer

Responsibilities:

• Airbus A300/600 Passenger to Freighter conversion
• Interiors and Structures.
• Created cargo door surround structure and assembly tooling models.
• SOW release for a door deactivation EO for the freighter conversion.
• Created a new Crew courier area ceiling design with Confidential duct and plenum integration.
• The secondary aircraft structural designs for the ceiling support systems had to meet FAA crew requirements.
• SOW created and RFP sent to in-house shop.
• Created designs of fuselage structure changes in the aft section for cargo bay door structure adaptation. UG NX5 and Team Center 9.0

Confidential, Ft. Worth, TX

Engineering Liaison/Specialist

Responsibilities:

• Military Redline effort AH1Z Cobra and UH1Y Huey early low production rate build.
• Wire Harness conformity and routing feasibility through structure mods. SOW shown through Red-lines on copies of 50 year old drawings. BOM updates, and tooling mods.
• Engineering Change Order planning was done.
• Flight line and floor engineering support for build team.
• Stack-up clearancing, chafing, edge margins, Int. mold-line check, clamp clearances, Subsystem integration tasks.
• Unigraphics MBD Parametric Modelling of Large Highly Complex Turbomachinery Gearbox Castings and complete drive trains.
• V22 Left and right main gearboxes modelled, along with Mid-wing and Tilt-Rotor
• Forgings and Machined parts for the V-22 Osprey and other Helicopter lines needing component changeover to 3D models in NX for the automated machining centers.

Confidential, Rochester, NY

Lead Designer

Responsibilities:

• Created a 47 custom component optical alignment fixture that had to be light weight and have multiple orientation capability with micro adjustability in 3 different axes, plus impart no stresses to 1.5 wavelengths to the primary optic. Theodolite final optical layout.
• SOW created for entire fixture build. RFP sent to 3 shops to bid. Clean room compliant.
• Designed and released a super-size 15 ton Structural Weldment fixture for vibratory testing. SOW created for entire fixture build. RFP sent to 3 shops to bid. Materials, cut, machine, weld, final machine, finish and 3D laser scanning of critical dimensions.
• Collaborated with numerous teams to insure facility support systems are in place for testing. SOW for special building modifications for large force systems required.
• Framework integrated into a 6-story test facility. Metal plates and concrete stanchions were specified to handle the loads. Integrated an isolation system into an existing Super Structure. Worked with steel suppliers for proper materials specifications with IPT evaluation. Electromechanical integration of multiple configuration layouts for final assembly Verification. Structural final checking.
• Utilizing custom designed fixturing and Optical Alignment tooling for extremely critical measurements. GD&T on all drawings using NX2.

Confidential, Rochester, NY

Senior Configuration and Tooling Designer

Responsibilities:

• Worked with vendors on Tooling for 6-sigma deliverable on a welded mainframes. UG V3 through NX2
• IPT lead Structure design and planning. Modular computer electrical rack structure & enclosure. 55% cost of an off the shelf system weldment plus injection Molded components associative trade studies. Confidential cooling and ducting system designed to reduce computer temperature fluctuations.
• Later specifications added to support a 300 Lb. structural load.
• Had lead IPT responsibility working with teams to achieve cost goals and delivery.
• Created a high-speed fuser concept layout, minimizing existing parts count and developed 2X: functionality from currently used Components.
• Service- ability and access designed for quick-change. Modular Drop in design fitted into existing machines with no modifications.
• Decreased service frequencies and downtime by over 50%. SOW created.
• Mainframe structure IPT responsibility meant also integrating all other sub-systems.
• Created Complete Confidential Thermal management IPT lead for machine environment. Created all duct work, manifolds hose routings, fan and blower sizing sound abatement and vibration reduction through multiple test evaluations of various manufacturers. Evaluated filters, hose, and duct inner surfaces for airflow capabilities and thermal effectiveness.
• Designed testing and evaluated data from thermal couples placed throughout the machine running at full load.
• Hundreds of Confidential ducts created in Stereo lithography and later rubber molded in various durometers for short run production testing. After Mfg. sign-off parts released and molded for prod.
• Exactly Constrained structural mainframes, Created one deliverable, Vendor trade studies, then RFP’s sent out.
• Created a new type of structure Weldment for eliminating Peripheral framework blocking access to internal sub-systems and achieved 6-sigma process for the complex Weldment. Went on site to the vendor shop creating the Weldment fixture to help create sequencing of the welded components for reduction of stresses. This sequencing gave the 40 key mounting points a six sigma deliverable. C&E analysis run for reduction in number and frequency of welds and effect of stress on structures.
• Prototypes were assembled and run with zero defects
• Over 150 new components created and built requiring no rework or redesign. On time under cost.