D. Edwards Email & Phone Number

Develop and simulate thermal management of OEM electronics solutions. Provided staff consultative support, manage, lead, and supervise thermal management efforts, thermal analysis, thermal engineering, as the main point of contact technical specialist for staff engineers for thermal/fluid and some stress topics. Utilize Solidworks, Flotherm XT CFD, FloEFD CFD, hand calculations, and engineering judgement providing mechanical design solutions for highly adverse automotive environments. Interface with design projects, core and application project teams and disciplines. Design, perform, and oversee tests. Mentor, lead, and guide project engineers, Junior engineers, and Co-ops. Generates parametric studies of design options and performs sensitivity analyses to support design decisions. Evaluate and develop novel intellectual property materials, components & solutions. Successfully resolved overheating issues with the next generation core development concept, passing Death Valley testing in a 120 deg F outside environment. Develop & evaluate core components & applications for OEM’s such as BMW, Audi, Ford, GM, Nissan, HKMC, FCA, Honda, Toyota, Scania, & Subaru.

Sr. Thermal and Structural EngineerRockwell Collins Aerospace/Raytheon Perform Thermal and Structural Analysis for commercial and military avionics, electronics cooling, utilizing Ansys Workbench, Ansys Icepak, and Siemens FloEFD. Performed various analysis per customer or project requirements. Generated formal report deliverables for presentation to customers. Collaborate with other internal engineers consulting on their designs. Scope included conduction, forced convection, natural convection, radiation, solar loads, steady state, and transient. Developed a general correlation for design engineers to use related to performance of units under test in a test fixture.

25+ years hands on experience in thermal-fluids, vibration, and stress mechanical engineering, design, & analysis from concept initiation phase, systems engineering, through integration, testing, ongoing operations, customer service, and field engineering. Covering brainstorming, prototype build & testing, retrofits, root cause analysis, diagnostics & corrective actions, component and sub-system design, thermal management of electronics, military & aerospace avionics, Tier 1 automotive electronics, disk drive storage servers, heat exchangers, pumps, jet engine hot gas turbine cooling (secondary cooling), de-icing valves. Ansys, conjugate heat transfer CFD analysis, SolidWorks Simulation, SolidWorks / FloEFD & Flotherm XT, Flotherm classic, Icepack, GFSSP Generalized fluid system simulation program, Femap/Nastran, hand calcs, Steinberg, conduction convection, radiation, laminar flow cooling, transient heating, thermal stresses, infrared imaging thermography, scripts, project engineering, and project management. - Resolved issues on the International Space Station (ISS) Internal Active Thermal Control System as a member of the Subsystem Problem Resolution Team & Anomaly Resolution (Tiger) Teams for US elements & Shuttle cargo bay interfaces. - Resolved with alternate solutions numerous difficult, critical, novel, major, multi-disciplined technical problems, ISS hardware, and system performance non-conformances and on-orbit performance anomalies. - Designed the Aries-I system integration and test facility (SITF & SIL) fluid based cooling system at a cost 1/ 3 of allocation. - Authored and oversaw pre-flight integration, test/checkout, designed lab bench tests for anomaly investigations, and maintenance procedures of the ISS internal active cooling system internal active cooling systems.

- Provided systems integration, engineering, and oversight of ISS elements (U.S. Lab, Airlock, Nodes).- Performed successful flight check-out testing on the Airlock cooling system at Kennedy Space Center. - Conducted successful (pre-) flight check-out of the ISS Airlock fluid system.- Experience in specifying, diagnosing, and testing thermal-fluid geometry, components, systems, heat exchangers, pressure vessels, ASME Section VIII Code, TEMA standards, nickel superalloys, platings, weldments, expansion joints, thermal interface, heat spreaders, underfill, adhesives, staking, fans, pumps, chillers, cold plates, vapor chambers, custom heat sinks, thermal planes, compact heat exchangers.

On-site contract project consulting engineering for military 3DELRR systems (3D extended long range radar) and S-280 shelter. Assist team in finalizing designs for and preparing for CDR. Perform structural stress and dynamic analysis of various transportation modes loads and environment stimuli with Femap 11.1-Nastran, Solidworks Simulation, hand calcs. Provide input to mechanical designs. Perform static stress, frequency response, random vibration, fastener analysis, provide margins of safety (M.S.), and solutions to mechanical designers.

Project consulting engineering thermal and fluid design, analysis, test, and sustaining engineering of aerospace components, subsystems, and test rigs. 1-D fluid and 2-D coupled thermo-fluid network simulations, 3-D thermal finite element models, and multi-physics computational fluid dynamics modeling of electronics. - Prepare technical documentation and present design reviews to OEM customers. - Customers include aerospace engine manufacturers (GE), power generation, and oil and gas firms. Design tests & write test plans. Cooling technology included impingement cooling with pin fins and film cooling. Utilized commercial and custom GEA software tools. - Review and evaluate hardware and performance against requirements for obtaining FAA certification.

Thermal management analyst and product development design engineer for high end leading edge OEM networked storage servers such as Cray, IBM, Dell, Google. Intel strategic confidential partner. Romley platform, Sandy Bridge. Design and analysis of a complex, flow limited, high packaging density, adverse space and environmental requirement cooling application.- Designed an innovative solution with off the shelf and custom heat sinks, heat spreaders, thermal interface materials, ducting, and flow balancing elements. Outsource contract manufacturers had initially refused the work as thermally impossible.- Calculated and balanced airflows and temperatures using hand, spreadsheet, and Flotherm 3D CFD-thermal conjugate heat transfer analysis for a complex multi-parallel flow system. 22M cells (utilized wall function w/o boundary layer mesh). Utilized Command Center for parametric studies.- Thermal engineering effort was commenced one year after initial preliminary electrical and board layout design, two months prior to critical design, yet the thermal solution was in place, prototype parts on-site prior to completion of electrical board bring up (booting) activities, and mechanical/thermal testing schedule. Simulations verified the design meeting all requirements to 40C ambient, 10,000 ft altitude, and fan fail conditions.- multi-layer circuit board layout to enclosure & system level. Conduction, convection, radiation, and joule-heating, static & transient, surface mount and hi-power density packages. Cold plates, heat exchangers, heat sinks, thermal interface materials, heat spreaders, vapor chambers.

- Thermal-Hydraulic systems analysis, design and engineering, RFQ’s, BOM’s. Design phases from concept generation and trade studies through fabrication, start up and operation of air and water based thermal control systems. Flotherm CFD, Ansys Icepak, Nastran FEA, hand calcs. - Analyzed and designed the thermal control systems for the Ares-I Upper Stage, Aft Skirt, & Inter stage Systems Integration and Test Facility, Systems Integration Lab, and Computer Avionics Integration Labs. - The systems also involved data center level floor plan density of enclosure racks for support electronics, loads, and simulators.- Authored and presented design data packages and proposals.

Nashville, Tn, Us

Staff Engineer support provided to multiple departmental efforts. Product was mainly high power density electronic power supply modules. A prime target of evaluation was product reliability. Performed Finite element (FEA) & CFD multi-physics thermal analysis for thermal management cooling and structural stress/strain, and vibration analysis on components and assemblies. Evaluated and assessed mechanical & thermal designs and performance. Utilized infrared thermal imaging thermography. Supported project design cycle phases from paper design through sustaining engineering, and field failures analysis.- Coordinated thermal engineering project & task activities.- Performed and authored inter-departmental thermal analysis and test reports.- Diagnosed root cause, determined resolutions & corrective actions of thermal-mechanical issues- Provided input to design and design reviews, preventing production run losses and schedule delays.(layoff work force realignment due to corporate restructuring)

Program support: Rotary, Fixed Wing, and ground vehicle platforms. Served as acting/working engineering analysis manager/engineer reviewing technical specifications & requirements to determine and delegate engineering work assignments and support marketing proposals analysis cost estimates. Coordinated project and task activities, Microsoft Project managment. Oversaw test contractors and coordinated analysis & testing. Review, evaluate, & assess designs & technical performance of contracted products against requirements. Assess and communicate risk to deliverables for upcoming project milestones.- Created and solved FEA & CFD multi-physics, mechanical, thermal-fluid, & dynamic analysis models. Linear static, stress, strain, displacement, transient, dynamic non-linear, frequency response, buckling, & bolted connections.- Dynamics included acceleration; sine, random, sine on random, & gunfire vibration; shock, pyrotechnic, and ballistic shock. Determined and adjusted natural frequencies and modal shapes. Experimental vibration testing. Thermal included natural & forced convection, radiation, conduction, thermal shock, & transient heating rates. Modeled and evaluated multi-layered polyamide PCB’s & components including ruggedizing needs.- Delivered contracted products to Boeing/Army Apache, Sikorsky/Navy CH53K, Lockheed/U.S.A.F. SAC C130, Boeing F-15, Army MRAP, and commercial aerospace programs. Avionics and communication equipment.- Authored, presented, and defended design review packages to military, defense customers, and independent oversight participants. Authored and delivered required technical data packages, summaries, and calculations.- Investigate and diagnose through analysis, inspection, and test structural and thermal-fluid problems. Oversee Mil-S-901D High Impact testing. Facilitate and moderate trouble-shooting activities and go forward plans as required.

- Thermal management & Mechanical Engineering, Design and analysis, FEA structural & thermal/hydraulic models, and application engineering of pressure vessels, heat exchangers, cooling systems, cabinet cooling, outside enclosures, rack, fans, blowers, cold plates, heat pipes, environmental controls, & AC.- ASME Section VIII calculations & documentation of pressure vessels, shell & tube heat exchangers, nozzles, supports, expansion joints, high vacuum systems, valves, gauges, sensors, and piping, including stainless steels & nickel super alloys. Seismic and Zick saddle analysis. Prepared documentation for the National Board Inspector. Generate design specifications and blueprints. Oversee ASME and TEMA shell & tube manufacturing.- FEA, hand, and MathCad calculations included structural stress, vibration, & thermodynamics of thermal-fluids. Fluid to fluid convection coefficients, pressure drops, super cooling, condensation, evaporation, sub-cooling.- Generate, maintain, & monitor PIDs, RFQs, pricing, BOMs, orders, & component quality control inspections.

* Supported International Space Station (ISS) program projects. Performed hardware component and system engineering tasks from concept initiation & trade studies through sustaining engineering and operational on-orbit maintenance.* Resolved issues on the Internal Active Thermal Control System as a member of the Subsystem Problem Resolution Team & Anomaly Resolution (Tiger) Teams for US elements & Shuttle cargo bay interfaces.- Resolved with alternate solutions numerous difficult, critical, novel, major, multi-disciplined technical problems. ISS hardware and system performance non-conformances and on-orbit performance anomalies.- Verification and validation of analysis and test methodology. - Defined, developed, and oversaw the ISS Airlock Module flight close-out testing methodology, criteria, and test procedures at Kennedy Space Center. Participated in the on-orbit activation.- Reviewed and assessed FMEA risk & hazard analysis line items against controls, test plans, & verification documents.- Performed analysis to support technical project program management. Prepare, summarize, provide, & defend rational for situation reports, status, & go forward plans to program boards such as Vehicle Integration Panel, Vehicle Control Board, Chief Engineer’s Review, Test & Verification Panel, & program safety regulation panels.- Manned the Engineering Support Room console as a technical resource for several real time missions.- Recognized as NASA subject matter expert on the ISS Fluid System Servicer.- Technical review & assessment to close findings related to performance, failure & problem reports. Disposition of hardware & subsystem non-conformances, non-compliance’s, problem reports, failure, repair, & anomaly investigations; test, tear down, & evaluation; solution oriented root cause analysis determinations, resolutions, & corrective action plans. System performance diagnostics utilizing mock up simulators & fleet leader test beds.continued ...

continued, - Monitoring and assessment of cooling loops’ coolant chemistry for troubleshooting and predictive maintenance. Coolant modeling - aqueous speciation software. Assess concentrations, precipitation accumulation potential, and changing pH. Analysis of gaseous permeation and diffusion for coolant contamination control & lab bench testing.

- Technology development of thermal-fluid inkjet technologies. Design lab R&D test fixtures, conduct experiments, characterize technology under development. Microelectronic-thermal-mechanical-fluidic devices.- Programmed & implemented a data acquisition system in C language, GPIB & HPIB data bus instrumentation.- Performed image analysis lab functions of printing processes.- Field engineering and customer service, diagnostics, root cause analysis, & corrective actions, retrofits, installs, start-ups, periodic maintenance, ongoing operations of high profile corporate data center’s high speed scanning laser printers and computer controllers. Rotating machinery, computers, peripherals, lasers, optics. Million+ pages per week per machine, 97% uptime, 24-7 support.

B.S.M.E., Mechanical Engineering, Thermal - Fluids

Certificate, Photographic Instrumentation

A.A.S, Photographic Technology - Imaging