Dave Pilon Email & Phone Number

Stratford, Connecticut, Us

Charlotte, Nc, Us

Performed complex electrical, thermal, flow, noise, vibration and structural performance testing of environmental control systems, air cycle machines, propellers, engine and fuel controls, hydraulic actuators, embedded electronics, heat exchangers, pumps, valves, ducting and other aerospace components.Created data acquisition, analysis and control applications using state of the art plug-in and stand-alone instrumentation, dynamic signal analyzers, signal conditioning, electronics, sensors and actuators. Expert knowledge of sensors including temperature, pressure, flow, humidity, speed, force, torque, strain, vibration, acoustic, magnetic, electrical, optical, gas/chemical, etc.Successfully developed general purpose low and high speed data acquisition systems, turbo machinery vibration, high cycle fatigue and acoustics testing, fuel control/pump diagnostics systems, propeller hub fatigue test rig, heat exchanger thermal cycling rig, impact and containment tests, thermography and high speed digital camera systems, Ethernet and CAN bus instrumentation networks, automated sensor calibration, modal analysis, lab data archival system, documentation database.Performed uncertainty analysis, data reduction and presentation using commercial and custom programs. Correlated FEA results with Modal Analysis and other test data.Extensive programming experience using object oriented and graphical software development tools (C, Visual Basic, LabVIEW). Expert knowledge of instrumentation interfaces, algorithms and DSP techniques. Developed real time control systems in C using Data Translation DT9842 (TMS320C6713) and TI Code Composer.Supervised, trained and mentored engineers and lab personnel performing rig construction, instrumentation selection, setup, calibration, testing and analysis. Prepared budget and cost estimates. Supervised procurement and testing using outside vendors and test facilities.

Developed novel tuning procedure for vibratory bowl feeders used to assemble plastic parts. Precise process reduces time to tune bowls from hours to minutes. Feed rate rates were maximized and jamming minimized.Performed FEA analysis and testing of ultrasonic welders used to assemble high volume plastic parts. Identified critical design parameters of parts and welders. Prepared test and tuning procedures to diagnose and optimize welder performance.Performed finite element analysis to predict fatigue life of an aluminum impeller used in a vortex regenerative blower.

Performed finite element and laminate analysis using MSC/NASTRAN and SDRC IDEAS to minimize mass, vibration, static and thermal distortion of high energy particle detector made of extremely precise composite parts.Redesigned detector modules to be supported by light weight graphite tubes. Static deflections and thermal distortion were reduced while also eliminating excess material. Cylindrical support structure made of sandwich construction was also redesigned so that all performance specifications were met or exceeded.Performed vibration tests of prototypes using B&K 2034 Signal Analyzer and PCMAP modal analysis software to validate FEA models.

Managed state of the art laboratory, machine shop and department computers.Extensive experience with mechanical and electronic test equipment including computer data acquisition systems, FFT analyzers, sensors, etc.Performed analysis and testing on a wide range of problems to solve design and manufacturing problems for local industry.Taught laboratory courses in Heat Transfer, Fluid and Solid Mechanics.Successfully developed computer code: Parameter Refinement Computer Code for Structural Dynamic Models (PAREDYM) for Sikorsky Aircraft Division of United Technologies Corp. System allows Sikorsky engineers to minimize aircraft vibration by using modal test results or design goals to update FEA models.Performed modal testing of composite fuselage mockup to demonstrate PAREDYM.

Responsible for mechanical design, manufacturing and testing of parabolic microwave antenna and waveguide pressurization equipment product line.Project manager for MCI cassegrain antenna mechanical design. Integrity of the design was verified by an outside consulting firm.Discovered design flaw in large antennas. Switch from channel shaped ring to torsionally stiff box section reduced sag by 50% with no increase in cost.Designed and supervised construction of wind/ice load test facility for antennas up to 15 feet in diameter.Developed algorithm to model the bending and springback of tubing for low wind drag antennas. Bending mandrel shape is automatically computed vastly improving quality over previous build and test method.Developed software to optimize cutter coordinates for Mazak CNC milling machine to maximize production of elliptical waveguide connectors given desired tolerance.

Bsme, Mechanical Engineering

Msme, Mechanical Engineering