Bob Allegretto Email & Phone Number

Northeastern University

Project Leader of Cold Spray and Automation and metal powder development at the Kostas Research Institute at Northeastern University. Working directly with the Army Research Lab at Aberdeen Proving Ground in Maryland and other military operations to advance the technology of Additive Manufacturing in repair of critical military and commercial components. Cold spray, also referred to as supersonic particle deposition, is a high-energy solid-state coating and powder consolidation process. Cold spray uses an electrically heated high-pressure carrier gas, like nitrogen or helium, to accelerate metal powders through a supersonic de Laval nozzle above a critical velocity for particle adhesion. The bonding mechanism is a combination of mechanical interlocking and metallurgical bonding from re-crystallization at highly strained particle interfaces.This technology will likely replace welding and flame spray in areas where high heat can not be used for metal repair.

North Andover, Ma

I will continue to work at developing LBS while transitioning to other full time employment. Working with clients to develop materials, provide prototype to production support, and fabrication processes for product creation. Assist with budgeting, proposal writing, developing technical information and specifications, and shop procedures. Development of Lattice Block Structures Technology, a light weight - high strength structural material for military, aerospace and commercial applications.Achievements:Provided materials expertise for selection, fabrication, and technical support for development of thermal management components for electronics products.Specialist in development of Lattice Block Structures technology and applications.(Note -company name change on Sept 1, 2014)

Lawrence, Ma

15 months as QC Manager and time to move on. I'm working on something bigger and better.

North Andover, Ma

Managed Division Operations and served as Program Manager of the Materials Development Team. Lead team of 10 to 25 employees in product design and manufacturing. Prepared proposals for technical design contracts with Department of Defense and NASA creating interim and final reports. Maintained management of projects and personnel, handling all aspects of technical design while managing the program budgets and facility.Achievements:Served as lead designer for development of lightweight temporary airfield matting for DOD. Developed product specifications with engineers and technical personal. Designed product and manufacturing process including fabrication, assembly, and testing while maintaining budget, preparing reports, and creating the final report. Successfully reduced weight while increasing strength and lowered cost from $2300 to $60 per square foot.Increased product weld precision and throughput while decreasing heat effected zone. In partnership with Penn State University served as lead designer developing high speed aluminum welding, perfecting a Laser Stir Weld process with speeds up 200 inches per minute increasing production 15 times over manual welding with an increase in weld joint strength of over 20% compared to traditional MIG welding.Designed thermal management components utilizing a copper coated diamond powder to dissipate heat from electronic devices. Developed economic methods to shape material for secondary processing and pre-production fabrication equipment to increase production and reduce cost. Increased production from 1 part per hour to over 60 in pre-production runs and developed equipment able to triple manufacturing output.Develop tooling and production methods for economic fabrication of Lattice Block Structure products to produce high-strength, lightweight truss structure materials for mechanical applications.

Andover, Ma

Performed precision gauge component design and development. Devised testing methods, tools, design, fixtures and fabrication for components. Prepared assembly instructions and developed test procedures.Achievements:Utilized SolidWorks CAD software to design mechanical components for a ceramic vacuum gauge. Developed product from concept to production preparing assembly procedures, tooling and fixtures for the completed gauge.ne-year contract position held while employed at FTG.

Wilmington, Ma

Served as lead designer for development of high strength watertight doors for US Navy ships. Managed a $1 million budget with a time line of over two years to complete multiple Small Business Innovative Research projects.Achievements:Developed mechanical design for watertight doors for US Navy with SolidWorks CAD. Determined specifications with DOD engineers at Navy sites and shipyards. Served as project manager and lead mechanical designer developing design patterns and tooling, worked with foundry to fabricate castings, and machine shops for finished castings. Performed prototype testing at DOD test site to meet military specifications. Designed high strength and lightweight engine containment ring for NASA utilizing an advanced material casting process. Performed mechanical design with SolidWorks CAD and worked closely with foundry to fabricate castings. Received favorable feedback for NASA for high tolerances and resistance to deformation. Worked with commercial engineers to design and develop high-strength, low weight flat surface mirrors. Developed successful production design with low cost.

Revere, Ma

Managed quality control for all aspects of production in aluminum casting facility. Coordinated customer design support. Managed facility and supervised maintenance. Served as night shift supervisor (1994-1995).

Designed illumination systems and optical components for semi-conductor production equipment. AutoTrol CAD design.