Executive Engineer - Composite Structures
Hethel, Norfolk
1985 – ’86 Development Engineer1986 – ’88 Senior EngineerOriginator of the novel BIW concept chosen for the Elan: 2mm thick non-shrink GRP body panels for high surface finish and accurate fit, preforming of glass fibre, soft bonding and SPR of steel peripheral frame..1988 – ’92 Principal EngineerResponsible for all body materials and design, assembly and repair processes for the new Elan. Engineered an alternative to boron steel door beam1992 – ’95 Senior Principal EngineerDeveloped a number of concepts combining advanced composites and aluminium; based on extrusions and die cast nodes, intended for Esprit replacement.Project Manager for Mercedes ‘A’ class prototype crash structure program, designed oil heated prototype tooling for press moulding of P/SR incorporating low cost carbon and natural (flax) fibres. Designed high performance epoxy tooling capable of pressing GMT in a 500 tonne presspatents: speed sensing energy absorber, ‘square wave’ knee bolster, non-linear stiffness chassis, oil condition monitorSeconded to Chevrolet Corvette C5 ‘bubble up’ team in Detroit1995 - ’96 Executive EngineerConcept design of the all-composite SMUD electric vehicle with innovative pultruded primary structure, BIW and closuresProject Manager for the Electric Elise, precursor of the Tesla Roadster.Originator of key technologies for Elise: aluminium chassis bonding process, composite to aluminium bonding system, RTM monoside, structural screen surround, and composite crash structure.Worked with GM engineering team on several spaceframe designs, mostly intended for low volume and niche products (e.g. Cadillac ‘2000’).Presented P/SR process at Autotech conference - a structural composite moulding process capable of 30 parts per hour1996 - ’97 Manager - ‘Business Development – Europe’ Joined the engineering sales team to sell vehicle engineering to European vehicle manufacturers.