SUMMARY:

Innovative engineering development position utilizing systems development, testing, analysis, and prototype fabrication of composite materials and technologies.

PROFESSIONAL EXPERIENCE:

Advanced Development Manager

Confidential, Michigan

Responsibilities:

• Collaborative development of pultrusion applications
• Developed polymer substrate technology that reduced product costs by 90% of current paint system
• Developed robotic automated system for composites with 3 mos ROI and reduced scrap by +40%
• Initiated material & process technology that was 40% less expensive and 60% shorter takt time
• Initiated alternative automated material and manufacturing process 1/3 the cost of a Confidential component
• Lead HP RTM composite structural demonstrator design effort, high strain rate modeling & test with cross functional team consisting of Fraunhoffer, Material suppliers, tooling, equipment, & an OEM
• Lead cross functional high volume NDE effort $150k phase I, $1.6M phase II effort with external & internal participants

Product Development Engineering Manager

Confidential

Responsibilities:

• Implemented ECN system with drawing/model file, Confidential & Confidential control systems
• Managed implementation of new applications & tooling innovations on patented press process
• Intellectual Property (local/global), patent filing, and patent maintenance oversight
• Initiated teamcenter interface for accessing/maintaining customer Confidential files and requirements
• Implemented engineering - lead holistic design for composites / DFM, and process optimization
• Lead development of proprietary press technology customer applications, filed IP on key provisional patents
• Direct supervision of lab supervisor, 6 engineers, and facility supervisor with 4 technicians

COMPOSITE MATERIAL SPECIALIST

Confidential, Michigan

Responsibilities:

• Lead cross functional external collaborative team to assist winning proposals of $70M
• Interim Engineering Manager ( Confidential ) of business jet composite winglet resulting in $23M contract
• Lead external Confidential collaborative development team of two other OEMs to secure $500k in funding for sponsoring agency, lead internal B&P team
• Individually fulfilled internal department goal for innovative solutions resulting in improved department capabilities, including ceramic tooling, LWT slat armor system demonstrator, and JLTV hood demonstrator
• NDE development of multifunctional energy management material systems to support production issues - saving $496k/yr for Confidential and external customer
• Collaborative efforts with Gulfstream on damage tolerant structural material systems
• Composite material design lead, interface with other IPTs including thermal systems, Confidential on lightweight low cost composite material projects, responsible for EVMS program reporting
• Design and Development of multifunctional composite material systems for defense applications

SENIOR COMPOSITE ENGINEER

Confidential, Dearborn, Michigan

Responsibilities:

• Principal Investigator of carbon fiber / epoxy composite driveshaft
• Established prepreg material specifications & coupon level thermal-mechanical characterization Developed bonded joint design, analysis, adhesive specifications & characterization Prepreg cure cycle development & process specifications (MPP) on three prepreg material systems Preliminary evaluation of non-destructive evaluation methods via ultrasound, thermography, and acoustic emission
• Principal Investigator of Electron Beam curing of structural PMC chassis components
• Lead Visteon effort in establishing a Cooperative Research & Development Agreement with Confidential Constructed a project scope of work and component system level specifications with Confidential participants Developed E-beam demonstrator design verification & process requirements verification plan Initiated preliminary E beam tooling designs and material selection for component fabrication
• Internal consultant on prepreg leafspring development, full scale chassis prototype design & fabrication
• Assessment of best practices in high volume composite processing methods
• Establishment of Visteon composite lab, equipment, test methods, and leaf spring material specifications

COMPOSITE ENGINEER

Confidential, New Orleans, Louisiana

Responsibilities:

• Coordinate $350k Mechanical test program activities for the graphite/phenolic nose cone requalification of the External Tank for the space shuttle program
• Supervised High temperature subcomponent testing for material specification validation for the composite nose cone
• Fabricated a 6' demonstration subcomponent for the leading edge of the proposed Joint Strike Fighter (JSF) via VARTM
• Internal Consultant for Photoelastic testing verification of Al-Lithium Friction Stir Plug Welding process 'A-basis' Allowables
• Developed hot press cure material process plan (MPP) for thermal isolator parts for the External Tank and X-33
• Materials representative on material review board (MRB) for nosecone, thermal isolator, cable tray, and inner-tank access door flight hardware
• Advised and assisted Tulane University undergrad students in the design, analysis, and fabrication of a structural uni-body for an vehicle

MECHANICAL ENGINEER

Confidential, Broomfield, Colorado

Responsibilities:

• Responsible for establishing customer design specifications and design & manufacturing of high performance composite seals and support rings
• Evaluated current compression molding methods via non-destructive evaluation
• Utilized data acquisition to evaluate slant coil spring production and establish process specifications

TEACHING/RESEARCH ASSISTANT

Confidential, Iowa

Responsibilities:

• Taught Strength of Materials laboratory to 25 undergraduates
• Administered tests; graded papers
• Tested graphite/epoxy composites, wood, and metallic materials on testing equipment
• Utilized ANSYS v5.0 and moiré interferometry to investigate shear strains in wavy layers of graphite/ epoxy laminates
• Used AutoCAD and AME software for three-dimensional wireframe and solid modeling
• Incorporated solid models into 3D Studio to create animated dimensioning and tolerancing tutorials