Daniel Polis Email & Phone Number

Louisville, Colorado (Co), Us

I'm currently leading Engineering Solutions at Sierra Space. Engineering Solutions includes the Advanced Manufacturing, Materials and Process Engineering (AMMP) group where we're innovating in additive manufacturing, catalysis synthesis, integrated composite structures, propulsion chemistry, thermal protection systems, as well as non-destructive evaluation methods. My group also includes Engineering Services, which is responsible for driving solutions into the enterprise through Liaison Engineering, Digital Pilot Plant development tools, CAD methods and tools, Non-flight mechanical equipment design, Librarian and Design Checking services, and Extended Reality/Virtual Reality tools.

Louisville, Colorado (Co), Us

Was responsible for bringing vertical integration to Sierra Space through the development of a new Materials and Process Center of Excellence. The center will bring advanced composite development, thermal protection development, and other advanced materials and processes on-line for use in Sierra Space’s key sectors (Transportation, Destinations, and Space Applications).

Sparks, Nv, Us

Managed an organization (>150 engineers) responsible for the subsystem design, analysis, and verification of the Dream Chaser® Cargo System. Included budget, schedule and technical management of Environmental Control and Life Support System, Electrical and Fluid distribution, Mechanical Systems, Primary and Secondary Structures, Propulsion, and Thermal Control Systems, Thermal Protection Systems. This included major technological development in Thermal Protection Systems (>3000F OML temp), Propulsion Systems (Peroxide Oxidizer), & Highly-Integrated, High-Temperature Bonded Composite Structural Assemblies.

Sparks, Nv, Us

Managed a team responsible for the design of a spacecraft (Dream Chaser®) planned for orbital flight, International Space Station services, re-entry and reuse. This includes the design of Electrical Harnessing, Fluid and Gas Tubing, Mechanical Systems, Primary and Secondary Structures, and Thermal Protection Systems.

Sparks, Nv, Us

Orbital Vehicle Design and Development (2012 – March, 2019):Managed a team to design, build, test and certify the Dream Chaser® Structure. Responsible for the build-to-print design of two major composite structures: a reusable lifting body spaceframe and a one-time use pressurized capsule (disposed during reentry after each mission). Received SNC’s highest award two times during my tenure for delivering a major qualification article and design handbook (2015 STAR Award) and for delivering one of the most advanced high temperature bonded assemblies in aerospace (2019 STAR Award). Serve as the subject matter expert in composite structures and have been brought in on projects outside of our business unit, including primary structure modification of existing composite airframes for DoD usage and a NASA structural failure investigations (Mars 2020).

Greenbelt, Md, Us

Composite Engineering Technology (2010 – 2012):Served as the team leader for NASA Goddard Space Flight Center’s Composite Technology Thrust. Led an interdisciplinary team to develop composite technology in several areas, including: monocoque design, 3D woven joining, and development lifecycle optimization. The Composite Crew Module (2007-2010):Served as the Materials Lead on the NESC’s Composite Crew Module program. Developed a comprehensive design methodology for a manned composite space vehicle by combining satellite and aircraft design philosophies. I provided overall technical authority for decisions across the design, manufacturing, testing, and inspection efforts on a daily basis. The impact of my role on this program was acknowledged by the 2007 NESC Director's Award and the 2009 NASA Exceptional Engineering Achievement Medal. The James Webb Space Telescope (2005-2007):Served as the Lead Materials Engineer on the Systems Engineering Team. Led internal and external teams to investigate high-risk materials issues, such as cryogenic composite performance for use in large ultra-stable structures and space environmental effects on polymer membranes. Successfully designed and led a study to optimize the cryogenic performance of composites, which has been incorporated into the two major composite telescope elements. The Hubble Space Telescope (2002-2005):Served as the Lead Materials Engineer for the composite Super-Lightweight Interchangeable Carrier (SLIC). Successfully led the structural materials characterization program to validate the use of high performance composite materials for use in the construction of a Space Shuttle Payload Carrier. The SLIC structure flew and landed aboard STS-125.

Boston, Ma, Us

Program Leader for ceramic technology used in high intensity discharge lamps. Directed a group of seven scientists/engineers responsible for new ceramic product introductions, quality initiatives, as well as productivity and capacity programs. Developed several patented technologies. Used Six Sigma Statistical Methodology in a manufacturing environment to improve existing processes and provide statistical control.

Doctor Of Philosophy (Phd), Materials Science

Bachelor Of Science (Bs), Chemistry