Summary
Creative and driven with over two decades in aerospace and marine maintenance, and mechanisms and structural design engineering; semiconductor equipment design; physical and virtual prototyping; fabricated metal structures design and engineering; system troubleshooting; cost optimization; and mentoring. DoD SECRET clearance thru May 2027.
Related Experience
Naval Surface Warfare Center Carderock Division (NSWCCD) and CSRA (formerly CSC) Advanced Marine Center D.C., Mechanical Engineer Senior October 2015 – present
All work performed securely for DoD/Navy, therefore simplified description: Specialized Vehicle Handling Dolly; Extra Handling Cart; Jack-Stand System; Nose-Lift Pallet Work with the customer to develop specifications for all four systems: good-better-best, must-desirable-dream. Design and engineer a suitable powered device (3-phase 208/440 mains power, at no faster than human walking speed, NOT an actual road vehicle) to meet all criteria, such as: human-factors / ergonomics, safety, manufacturability, environmental protection, longevity, operating speed and payload capacity. By careful selection, the design mainly consists of COTS equipment, such as typical industrial gears/sprockets/bearings, and forklift tires.
Assisted customer in defining/specifying the Nose Hinge/Latch System to be incorporated on the LDUUV. Developed functional concepts for both the hinge and the latch. The hinge is a typical metal set with polymer bushings. The latch system contains linkages, cams, levers, and a mechanical conditional NOT / AND / OR computer to prevent damage / jamming.
ASRC Federal at NASA Wallops Flight Facility, Senior Principal Mechanical Engineer
December 2012 – October 2015 (initially with CSC for two years; contract roll-over)
Science Payload Integration, Lockheed C-130 “NAAMES 2015” Integrate two vacuum pumps, a liquid-nitrogen dewar; design / engineer / integrate a gas-bottle rack with up to 9 “K” bottle capacity; using both SolidWorks and Inventor. Ensure all vibration (natural frequency, and 68-Hz excitation from aircraft) and inertial / crash loads are met structurally. Manage PDR and CDR, procurement and fabrication, assembly, payload integration, and testing.
Science Payload Integration, Lockheed C-130 “IceBridge 2015 Arctic” Integrate two topographic-measuring LiDAR units into the existing floor porthole framework. Integrate two digital-SLR cameras on a vibration-isolation frame. Validate and optimize structure for vibration and yield performance using COSMOS FEA. Manage PDR and CDR, procurement and fabrication, assembly, payload integration, and testing.
Hatch-latch Engineering, Lockheed C-130 “4STAR ARISE 2014” Invent and design new latch mechanism system for the cockpit emergency-escape hatch to allow mounting up to 75 pounds (payload) on (thru) the hatch, while preserving the tool-less quick-removal escape functionality. Perform kinematic optimization of cams and four-bar linkages, COSMOS structural optimization. Manage PDR and CDR, procurement, assembly, payload integration, and testing.
Test GSE Engineering, “CREAM” Perform COSMOS weight reduction within defined positional/stiffness parameters of the vibration table expander head to allow testing of the payload to specified g level in all three axes, with one adapter. Interface with the subcontractors to ensure that the proposed design can be built to both cost and schedule targets.
RQ-2 Pioneer UAV Though existing flight hardware (engine, wings, etc) was still airworthy, spare flight-control servos were no longer commercially available. Continued on with prior replacement program to source new servos, and integrate with existing flight structure.
Test GSE Engineering, “LDSD” Perform COSMOS weight reduction within defined positional/stiffness parameters of the vibration table expander head to allow testing of the flight payload to 60 g level in all three axes, with one adapter. Interface with the subcontractors to ensure that the proposed design can be built to both cost and schedule targets.
Space Payload Engineering, “ISS-CREAM” Structural FEA using Pro/E Mechanica of small elements of the experiment. Design/engineering of the thermal/cooling loop of the experiment, including simple COSMOS CFD. Design/drafting of components using Inventor.
GSE Engineering, mission “LADEE” Design/engineering of mechanical GSE. Design and perform FEA optimization of support hooks for grate lifting using SolidWorks COSMOS. Perform safety/stability calculations of various stack configurations. Procure Clean Tent to improve cleanliness capabilities of fueling building from global class-100k to 10k (in tent).
Contract Reporting Collate both weekly and monthly task/labor reports that Program Managers use to verify completion and billing with customer.
Engineering Works, Owner October 2003 – November 2012
Design and Manufacture for
Best Bath Systems — invent/design/engineer/build/install 2-axis hydraulic press; in production use for 7+ years; smaller production equipment; consumer-product COSMOS FEA; invent/design/engineer/build/install 8-axis automated trim machine. This machine does the work of four operators in 72 aggregate minutes with one-half operator in 10 minutes. Project duration two years, $150k. Make SolidWorks part and assembly models, drawings, and BOMs. System integration of structural, pneumatic, electrical, and PLC components. Invention of three-action hydraulic “pincer” for mold management; from the fork-truck seat, the pincers: tilt down to horizontal, grasp the fork tip, pinch onto the mold frame to allow vertebra-saving handling of up to 500-lb fiberglass molds.
Kim Co — mechanical packaging of electronic components, printed-circuit assemblies, and subassemblies. Solidworks models, drawings, and BOMs.
Western World, Inc (aka Circle J Trailers) — mechanical design and COSMOS FEA engineering optimization of aluminum and/or steel horse and cargo trailers up to 14,000 pounds gross weight. Generate complete part / subassembly / top-level BOMs in SolidWorks. Training of in-house staff on AutoCAD, SolidWorks, and how to port drawings from AutoCAD (2D) to SolidWorks (3D). Forensic investigation of failed/abused trailers to determine root cause, and any necessary corrective action (repair, redesign).
CTI Aerospace — mechanical design and COSMOS FEA optimization of both onboard water filter systems and trash compactors for commercial and business aircraft. Drafting and design of parts/assemblies/drawings to FAA-level drawing and documentation standards.
Ionco Inc — design/engineering/construction of customer-patented automated fruit picking robot. Structural design, servomotors, gearboxes, bearings.
Diversified Fluid Systems — mechanical design and engineering of wet-processing equipment for the semiconductor industry. SolidWorks models, drawings, and BOMs. Export DXFs for CNC router processing.
Comprehensive Precision Machine — design of various mechanical projects, including Locomotive Sand-fill Door for Motive Power.
TDR Services — feasibility study of combined functional storm/window-shutter solar panel/heat pump/air conditioner for a “green” clien...
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