Darryl Malone Email & Phone Number

Ottawa And Gatineau

Senior Motor Vehicle Defect Investigator- Conduct top level motor vehicle investigations with respect to allegations of safety related defects. - Communicate with major motor vehicle manufacturers regarding motor vehicle safety issues.- Communicate with the general public and media during investigation for the purpose of gather information and informing the public. - Use knowledge of Canada Motor Vehicle Safety Act and Canadian Motor Vehicle Safety Regulations for the purpose of conducting motor vehicle defect investigations.- Perform detailed component failure analysis of motor vehicle safety system components through physical examination, the use of microscopes, photography and various other equipment.- Determine the cause of a failed component through the use of established failure analysis techniques and fractured surface examination.- Create testing procedures for the purpose of validating the operation of motor vehicle safety systems. - Use various data acquisition systems for testing of motor vehicle safety systems.- Use knowledge of vehicle dynamics for test-driving various motor vehicles to determine level of proper and safe operation.- Create detailed reports using Microsoft Word, Excel, Adobe Photoshop and digital images.- Motor vehicles include on road car and trucks to off road ATVs and snowmobiles.- Active member of the Road Safety building Occupation Health and Safety committee.- Assist with shop tool and equipment purchases- Work in both singular and a team environment during investigations.- link to department http://www.tc.gc.ca/eng/roadsafety/safevehicles-defectinvestigations-index-76.htm

- Designed various motorsport chassis, suspension and body components using aluminum, steel and Composites in the form of castings, extrusions, machined parts, welded assemblies and adhesive bonded assemblies.- Coordinate component and system projects from concept sketch, design review, CAD design, detailed drawings, prototype build, manufacturing and testing. - Designed several testing apparatus and testing procedures.- Produced detailed drawings for manufacturing purpose which included Geometric dimensioning and tolerancing.- Used mechanical design, mathematics and physics principals for the design of race car parts. - Used Geometric dimensioning and tolorencing to ensure high precision / tight tolerance designs.- Thorough understanding of 3D CAD modeling systems included SDRC Ideas, Catia V4, PDGS, Solidworks, Unigraphics and ProE. Some knowledge of NX7.5- Worked directly with the manufacturing shop to ensure product, assembly and timelines were on schedule.- Worked in a team environment to ensure the product and or race team was ready on time and 100% ready to go.- Direct hands-on, assisted with manufacturing, assembly and testing.- Worked extra long hours to finish design to be ready for next race.- Composite design included wet and pre-preg layup. Both with the use of an oven and autoclave. Design included component and mold. - Aluminum and steel components include; uprights, control arms, chassis and various other brackets. - Wiring harness and hydraulic hose/line layout.- During design I preformed preliminary FEA on the component prior to final design being sent to FEA department.- I was also responsible for CAD data transfer between parent company and clients.- Components were designed for the following race cars; Ford Daytona Prototype, Ford Mustang FR500, Panoz LMP, Porsche cup car and Petty Enterprise NASCAR. Also design production quality carbon fiber body work for Ford Focus Hydrogen fuel cell car.

- Work with a team of designers to bring military products from conception to production- Designed enclosures, wiring harnesses, telescoping mast, various brackets and retention devices- Use CAD software to generate 3-D models of mechanical and electrical components.- Used FEA to validate component strength and stiffness- Used simulation software to validate mechanical movement of assemblies- Use CAD software to produce detailed drawings- Design and research of mechanical and electrical components.