Dan Cousins Email and Phone Number

Mechanical Design Engineer for Rolls Royce.

The role of a Rolls-Royce Stress Analyst involves performing Finite Element and Hand Calculation analysis of the mechanical properties of complex sheet metal and 3D printed components, Ensuring that all components will perform safely and reliably in the engine environment, assessing fatigue life of components and Thermal and Vibration loads.The role involves liaising with Design, Component Definition, Manufacturing, Repair and Overhaul, Sub-System, Whole Engine Measurements and more to ensure that the most accurate and thorough analysis possible is carried out to facilitate delivery of safe, quality components on deadline.

Based within the specialised fabrications SCU, I am responsible for taking design solution concepts and liaising with suppliers, stress, aero and manufacturing to create precise 3D models/assemblies and specifications that ensure all components achieve right first time manufacturability and perform perfectly on the engine.My advanced solid/surface modelling abilities with Siemens nx and in-depth knowledge of Teamcenter PLM coupled with my previous manufacturing experience make me a valued member of the component definition group and a go-to source for design for manufacturing solutions.Specialised fabrications is responsible for the design and manufacture of extremely complex components such as aerodynamic fairings and also complicated bracketry and engine mountings.I am also responsible for training apprentices/interns.

For 8 months I was made Interim Team Lead of the complex fabrications SCU Component Definition Group whilst the current team lead was seconded to support another SCU. This involved, evaluating, planning and delegation of modelling and definition tasks within the team to meet 3 Trent Civil Large Engine projects (XWB 84k, XWB 97k and 1000 -TEN) deadlines. I also had to manage resource to support the BR700NG CSME delivery with R-R Deutschland.

During my time with Jaivel I spent 16 months onsite at Rolls - Royce Hucknall. I was a fully integrated member of the NPI team in combustors and casings as a manufacturing definition engineer. This exposed me to a broad spectrum of manufacturing techniques and technologies. I was responsible for creating manufacturing stage models and drawings which meant that I had to have a sound knowledge of manufacturing technologies and their capabilities in order to call out the correct standards/specs in my drawings. I was also responsible for tool and gauge design which requires a sound ability to calculate and apply tolerance stack ups and also a good appreciation of feature inspection processes.During the remainder of my time with Jaivel I worked in both technical and project management roles on numerous projects for major manufacturers/ suppliers including: Rolls-Royce, Airbus, Bloodhound SSC, CW Fletcher, CAV Aerospace, etc.Due to my expertise with Solidworks/Siemens NX coupled with my draughting skills I was usually the first stop for 3D modelling and draughting related solutions.