Aaron Caba Email & Phone Number

Radford, VA, US

London, GB

* Responsible for structural and thermal performance of new tactical rocket motors.* Conjugate heat transfer and charring simulations to predict performance of internal rocket motor insulation.* Developed a two-way coupled fluid-structure interaction (FSI) simulation of energetic material extrusion dies. End goal is to reduce trial-and-error approach to.

Durham, NC, US

• Perform coupled thermal, structural, and electromagnetic finite element simulations in ANSYS to show that micro fabricated RF devices (.5” x.5” x.040”) meet aircraft and MIL-STD environmental requirements such as.
• Design packaging and tooling for micro scale RF components with 3-D CAD. Ensure that designs meet internal and external customer requirements through design reviews. Document designs through ASME Y14.100 and Y14.5.
• Champion standard engineering processes such as design reviews and engineering standards to improve engineering execution as company transitions from single-designer paradigm to multi-person teams.
• Implement and administer SolidWorks Enterprise PDM document management to store and share 3-D CAD data throughout the company. CAD data now available to geographically separated groups: engineering, fab, assembly.
• Mentor younger engineers to help them develop engineering judgment and engineering discipline.
• Help identify skills and resource gaps based on program workload. Write personnel requisitions to help fill those gaps.

Dulles, Virginia, US

• Lead mechanical engineer for the new GATR guided missile system. Missile cost is 60% less than currently fielded system. New system is much lighter and allows aircraft to carry seven GATR missiles at the same overall.
• Customer-centric approach to solving problems. Works to understand customer requirements and schedule before beginning work, and to make sure that goals are clearly agreed upon from the start. Uses information to.
• Designed and analyzed fin deployment mechanism. Resulting design was on schedule and functioned as expected the first test and every ground and flight test since. Used coupled computational fluid dynamics (CFD) and.
• Validated simulations through rigorous bench testing and flight testing of the missile system.
• Showed initiative to independently recognize and create solutions to engineering procedures. Drove implementation of PLM software to replace paper and common drive systems.
• Designed precision aerospace components using 3-D CAD from concept through manufacturing.

Blacksburg, VA, US

• Dissertation Title: “Characterization of Carbon Mat Thermoplastic Composites”Advisors: Dr. Alfred C. Loos and Dr. Romesh C. Batra
• Studied the manufacturability and mechanical characteristics of a new composite material.
• Material allows the use of compression molding technology to manufacture near-net shape parts.
• Tested the mechanical strength and stiffness of molded parts.
• Performed rheological studies using a heated squeeze flow fixture and single fiber pull-out fixture to find the flow characteristics of the material in conditions similar to manufacturing environment.

Developed a material testing program to characterize new composite material systems including mechanical and fire testing. Used the test results in an industry-standard finite element program (MSC/NASTRAN) to quickly design large-scale composite structures including pedestrian and vehicular bridges. Performed accurate cost estimates on all designs and.

Blacksburg, VA, US

• Thesis Title: “Verification of a Three-Dimensional Resin Film Infusion Process Simulation Model”Advisor: Dr. Alfred C. Loos
• Integrated stress, thermal, and flow finite element formulations into a coherent multiphysics analysis model to simulate the manufacturing cycle of carbon-fiber composite materials.
• Validated the model against test cases run at Virginia Tech and by the research staff at Boeing.
• Presented biannual updates to Boeing to detail progress and results.

Ph.D., Engineering Mechanics

M.S., Engineering Mechanics

B.S., Mechanical Engineering