Stefan Ball Email & Phone Number

Seal Beach, California, United States

• Structural airframe repair analyst for 737 NG/MAX fuselage department• Develop and analyze repairs for CFR compliance• Well-versed in static and fatigue analysis• Understand principles of damage tolerance / crack growth• Identified as top performer by several experienced stress analysts/approvers• Self-motivated worker: Well-known for working on most difficult tasks; ‘Analysis junkie’• ‘Go to’ stress analyst for service engineers• Well-known for AOG support• Consistently ranked in the top ‘jobs done per week’ measurement• Designed and analyzed repairs for fuselage components including:• Skin (common) * Frame (common, inner/outer chord, web) * Window frame (pilot, passenger) * Floor beam * Bulkhead: Pressure / non-pressur

• Published and defended master's thesis: Numerical and Analytical Modeling of Temperature Evolution in Laser Processing of Materials. Built two simulation models to directly solve for time-dependent temperature gradients. Numerical model built through commercial software, Flow3D, to solve process iteratively. Analytical model built in MATLAB through heat transfer theory found in literature to solve process directly.• Wrote and presented: Statistical Analysis of Porosity and Process Parameter Relationships in Metal Additive Manufacturing. Used numerical methods (N point correlation functions) to represent porosity of additively manufactured parts and implemented in MATLAB. Successfully predicted, with experimental verification, porosity in laser powder bed fusion parts as a function of scan speed and laser power.• Developed direct energy deposition simulation in Truchas for analysis of thermal gradients. Scripts written in Fortran & C++.• Used Coreform Cubit to generate advanced hexahedral meshes for fluid flow and heat transfer.• Developed python scripts to automate laser path, deposition, and mesh generation.• Processed simulation data using MATLAB and python. Python used to automatically pull data to desired locations.• Wrote software and process instructions and provided support to group members to run simulations for similar projects.• Used ANSYS to develop a stress transfer, debonding, and fracture model in single fiber composites.• Utilized shear lag theory and a cohesive zone model to develop fiber/matrix interfacial stress and debonding model. Results show promise for furthering shear lag theory to relate applied tension of the matrix to debonding of the single fiber.

• Worked collobaroratively on project to detect fowl impacts, primarily eagles, on wind turbines.• Iteratively drew full-scale model of 1.5 MW GE wind turbine generator in SolidWorks.• Built electronics enclosure for camera and monitoring equipment.• Sourced and purchased enclosure. Modeled in SolidWorks and made necessary adjustments to allow for camera view and monitoring equipment.• Designed and modeled all brackets and fixtures for fixturing equipment and a dampening system for the camera bracket. Printed brackets using ABS plastic on FDM machine.• Produced IR testing kit report used for sourcing IR camera enclosure and protection lens.• Used ImageJ and MATLAB to report pixel density of cameras using interpolation and extrapolation of lens data.

Corvallis, Oregon, United States

• Produced technical documents for engineering reports, procedures, and proof of design.• Designed, purchased, and assembled mechanical assemblies using standard mechanical engineering design principles.• Used standard shop equipment to diagnose and repair mechanical and electrical products.• Designed disassembly procedure for stator and stator carts.• Designed and fabricated table structure for disassembly of stator and stator carts.• Performed electrical testing of stator components.• Designed several technical supporting assemblies for implementation into the nacelle and for disassembly and repair. Produced a SolidWorks CAD model and full report for each part.• Designed and sourced parts for water drainage system of Nacelle. Used PVC piping and standard pump.• Designed and sourced parts for ‘panhard’ bar used to secure longitudinal location of stators in rotary assembly.• Supported design and part sourcing of hydraulic press assembly used to remove rusted stator components.• Designed and sourced antenna and antenna assembly for GPS, GLONASS, and Iridium communications.• Performed thermal analysis of Nacelle greater assembly to calculate cooling power for tropical environment.

Corvallis, Oregon, United States

• Manufactured chassis for new Eco-Marathon Prototype Vehicle using carbon fiber pre-preg and steel molds.• Optimized efficiency of competition vehicle body by performing airflow analysis in SolidWorks.• Designed and manufactured chassis parts using steel, aluminum, and plastics. Utilized free body diagrams to ensure that parts met strength requirements.• Placed 2nd at Shell Eco-Marathon Americas 2019 in Prototype battery-electric division with a fuel efficiency of 234.4 mi/kWh or 7,900.5 MPGe.

• Used SolidWorks as primary CAD software to draft custom manufacturing projects and to update obsolete AutoCAD manufacturing drawings.• Completed several designs of steel fixture assemblies for composite manufacturing.• Drafted several custom projects, including a composite hopper structure used to transport weight-limited sand loads on semi-trucks. • Completed 23 pages of technical drawings for the manufacturing of a sand filter wastewater treatment system to be installed at an industrial site in British Columbia.• Used CAMWorks to program CNC operations. Operated 3-axis CNC mill to produce parts. Parts cut on CNC mill include custom signs and parts used in greater fixture assemblies.• Used AutoCAD to update floor plans for efficient manufacturing.• Designed and drew new shop floor to optimize process flow of laminate sheet manufacturing and packaging.• Completed set design of new products for a trade show in SolidWorks.

Master Of Science - Ms, Mechanical Engineering: Advanced Manufacturing, 3.75

• Master's Thesis: Numerical and Analytical Modeling of Temperature Evolution in Laser Processing of Materials. • First Author.

B.S. June 2020, Mechanical And Manufacturing Engineering, 3.90