Dave Kowalczyk Email & Phone Number

Guilford, Ct, Us

Atlanta, Georgia, Us

Kent, Wa, Us

-Developed high performance PC-based CNC control software (TurboCNC) and related embedded control products from scratch, programming mainly in Pascal and x86 assembly language. - Customer base is approximately 15,000 users worldwide and includes some "household name" companies. Projects are small to medium-sized (2,000 to 85,000 lines of code).-Managed the entire software development cycle from design through implementation, sales & marketing, and maintenance/customer support. Employed 2 contract programmers at the peak of business output in 2006.-Produced process control software for specialized operations such as jewel setting and motor field winding for industrial customers.-Educated newcomers to the field of CNC retrofits and machining through seminars, direct support and web articles offering tips and correcting typical misconceptions.-Redesigned a coffee mug printing press for manufacturability. The revised press has 75% fewer parts and prints far more uniformly than before.-Manufactured prototypes and short-run turnings on personally built custom CNC machines.-Designed and fabricated custom tooling for small-parts sheet metal forming.

Bristol, Ct, Us

-Designed a vision inspection station for confirming grease application in automated assembly of beard trimmers. The station inspects 900 assemblies per hour. -Designed machine frame, robotic internal seal inspection, cleaning, and final heat seal for production of “luer-lock” disinfectant caps used in medical intravenous dispensing applications. 9000 caps/hour.-Designed cam-driven sealed packaging can assembly stages for airborne disease diagnostic test kits. 3600 cans/hour.-During a lull in workloads, created a macro based internal design verification tool that automatically inspects SolidWorks assemblies and generates a report of incorrect threads, questionable mates and materials, and potentially mis-toleranced features which was extremely well received by the engineering team.-Developed performance enhancement proposals for legacy equipment from initial concept through detailed cost and schedule and written quotations.-Maintained an in-house C# application for face cam calculations and automated drawing/model generation after the original author left the company. Feature improvements and bug fixes, roughly 10k lines of code with some interfacing to internal databases.

Branford, Connecticut, Us

-Designed a thrust reversal proximity switch for the Falcon F6X aircraft. Scope of work included mechanical, electrical, and production tooling design as well as customer relationship management and project/resource scheduling.-Assigned to lead the turbine engine sensor upgrade for the Chinook CH-47/MH-47 helicopter. Sensor suite measures turbine speed, pressures, and oil temperatures in real-time to improve engine performance.-Promoted internally to Senior Design Engineer and appointed to lead the sensor design program for the TS1400+, a fully new turbine engine for the Turkish TAI T625 and T129 ATAK helicopters.

Kent, Washington, Us

-Responsible for ensuring the successful deployment of CNC water jet cutting tables manufactured offshore – WaterjetPRO® , Mach 2b and M-500 product lines. Over the last decade these products have brought revenues of about $45 million USD.-Designed custom robotic water-jet cutting systems for industrial customers in diverse applications: some examples are tires, mirrors, toilet paper, and residential siding. Responsible in a direct role from initial quotation and feasibility assessment, project schedule and staffing, through design/mfg and final acceptance.-Developed custom software for radius compensation programming KUKA robots. This was necessary for a particularly unusual customer application – an example of something that “couldn't be done,” until it was.-Received a promotion to Lead XY engineer, supervising a team of 8 engineers & designers working on all the “Standard Systems” XY tables in Jeffersonville, Indiana.-Designed the Mach2c shape cutting system (a CNC robotic gantry waterjet), then guided its implementation and roll out to production. Product was manufactured in Jeffersonville with a revenue of $5 million/yr.-Promoted again to Staff Mechanical Engineer, responsible for a broad range of development projects as well as mentoring junior staff.

Renton, Wa, Us

-Responsible for design, prototyping, and implementation of all mechanical systems on industrial machine vision and automation products. Typical sub-project categories were cameras, illuminators, industrial PC computers, and structural integration into the customer's factory. -Designed and built dedicated machinery for inspection and sorting of DC motor field magnets. Unit is currently operating in North Carolina. Projected sales are for 8 units at $200,000 each. -Designed and built a production line for inspection, cutting, and sorting of "bare root" seedlings. Projected sales are for 20 units at $750,000 each. Unit is currently operating in Washington. -Designed and built a six axis tire sidewall inspection robot. Projected sales are 20 units at $75,000 each. Unit is currently operating in Tennessee. -Manufactured miscellaneous sales demo and pre-production prototypes in house. Designed and built electrical systems and wiring harnesses as needed when the electrical engineers were overloaded. -Received promotion to manager, overseeing a technical designer and machinist, and production staff as necessary. -Resolved outstanding production issues with legacy products as needed.

Arlington, Va, Us

-Researched solutions for production and safety concerns in aircraft fuselage structure such as bulkheads, the passenger/cargo floor interfaces, and various fuselage skin and frame joints.-Coordinated with engineering liaison, production, and planning groups to implement changes into the production schedule.-Created and revised existing CATIA datasets including detail, assembly, and integration drawings and related parts lists.-Assisted in the introduction of LEAN principles on the engineering level by producing process documentation and presenting findings and suggestions for upper management.-Earned superior performance reviews.

Ames, Iowa, Us

-Responsible for all mechanical systems on multiple non-destructive testing projects.-Designed and constructed a 70' mockup of natural gas pipeline with a servo driven inspection tool to serve as a test bed to simulate crack detection in the field. Scope of work included motion control, position detection logic, and safety systems.-Designed and supervised initial construction of a 4 axis computer controlled fixture to simulate the in-patient inspection of artificial heart valves for early fatigue failure-Fabricated components personally using conventional and CNC machine tools to meet schedule demands. Was recognized for being a team player in this respect.-Coordinated workload where appropriate with vendors, and was responsible for purchasing/pricing services competitively.-Created project documentation and planning material; served as spokesman/liaison for the mechanical group during periodic project meetings and for visitors from outside the college.-Mentored student employees.

Bachelor'S Degree, Mechanical Engineering

Associate'S Degree, Mechanical Engineering