Responsible for the product/component design for wind turbine blades; use of epoxy-matrix composites; material qualification to meet requirements; blade fulfillment (ensure that production meets volume); design and analyze tests, blade trials, determine defect acceptability levels, responsible for material testing and preparing specifications (manufacturing, material, and design); computer modeling of the blade manufacturing process; infusion, prepreg lay-up, open and closed molding; create allowables (stress levels); extensive problem solving and problem resolution. Key Achievements:•Received GE “Outstanding Technical Achievement Award” for material design of wind turbine blades.•Published 15 patents in area of composite design for wind turbine application.•To reduce cost supported and facilitated activities to adapt design including adhesive reduction and lay-up adjustments into manufacturing process of fiber reinforced composites (FRC) at suppliers worldwide for GE; directed efforts and resources for fabrication of test blades.•Charged with validating bond integrity of prototype FRC blade with non-destructive techniques for GE; utilized non-conventional techniques to stay within budget and time constraints; formulated inspection plan, authored shop trial method documents, and assisted supplier with development of a custom-made crawler to move inside blade and transmit real-time video signal of bond lines; successfully inspected and validated blade.•Assisted to lead transfer of new blade technology to improve manufacturing production for GE; collaborated with design team to fine-tune and redefine manufacturing method; supported qualification testing and spearheaded activities related to fabrication of FRCs and process and material characterization/qualification of main components; improved fracture toughness of a key interface; led project for modeling oven for curing FRC components; met most objectives before process terminated due to financial situation.

Reported to the Director of Engineering in the US, providing leadership for blade processing and feedback to structural engineering; ensured blade fulfillment, material qualifications, and troubleshooting of blade processes; worked closely with raw material suppliers and consultants to carry out outsourced testing and inspections. Key Achievements:•Addressed blade process issue with minimum negative impact to production; formed a cross-functional team that resolved problem in a timely manner.•Led a non-destructive inspection project with an outside consultant for designing and mechanized blade bond line inspection. The final design and procedures were cut-in production. •Led project on the optimization of adhesive; designed a simple tool for the application; organized a trial and prepared functional specification for production scale use; efforts reduced cycle time and improved bonding.

Reported to the Wind Turbine Blade Manager; developed manufacturing process for new blade designs to include process modeling, heat transfer, and thermal stress issues; infusion, prepreg and lay-up; process specifications; provided product support and troubleshooting; conducted trials; assisted with projects and measures to improve quality and reduce costs; led theoretical process modeling activities; led non-destructive testing of blades and activities related to tool and mold validation; directed efforts related to material qualification testing; fostered relations with blade suppliers worldwide. Key Achievements:•Directed new development project involving new processes and materials under budget and time constraints; defined short- and mid-term plans, targets, and project scope.•Supported introduction of new blade design - AeroElastic; reviewed drawings, facility capability, labor force, and developed process work instructions; recommended using other facilities due to labor and facility situation.•Introduced and implemented major process and design changes to standard blades’ manufacturing processing at Brazil facility; led studies prior to executing fabrication of blade on time and at a considerable cost savings both in labor and materials; efforts led to receipt of the “Global Employee Award & Recognition” in 2005.

•Curtailed manufacturing cycle time of composite calender roll cover by 50% without compromised properties for Voith.•Prevented a premature failure of composite calender roll covers for largest Global customer; increased life of composite by 50%.