David Fusco Email and Phone Number

Test conductor for pyrotechnic shock testing of Solid Rocket MotorsPrepare procedures and oversee technicians during setup and firingProgram, setup, and operation of data acquisition systems to collect shock data during test

Commissioned and created procedures for the operation of new FARO Laser Tracker and Polyworks software package. System is used for tooling and spacecraft dimensional inspections.Created operating procedures for large Tenney Thermal Vacuum Chamber used for spacecraft thermal testing.Performed mechanical assembly of various spacecraft busses and components.

Payload and Launch Operations• Prepare planning documentation and oversee integration and checkout of spacecraft and various deployment systems (Dispenser and Lightband).• Payload Fairing encapsulation including associated ordnance/pyrotechnic operations.• Coordination with management and mission managers regarding integration status, anomalies, etc.• Monitor and maintain ISO 8 cleanroom payload processing facilities to ensure compliance with particle count, temperature, and humidity requirements. • Performed check out, commissioning, and first-time use of new ground support equipment for Encapsulated Payload Assembly horizontal mate to Rocket and Rocket transportation/mate to 747 Pylon for launch. • Support final launch operations in Mojave California and Spaceport Cornwall United Kingdom.

Production testing and check out of flight propulsion and fluid systems for various satellite programs. Proof, leak, and functional testing of spacecraft systems including propulsion tanks, thrusters, heat exchangers, mechanical fittings, valves, etc. Vacuum loading of heat exchanger fluid into flight pumped fluid systems followed by system checkout pump operations and data collection. Member of Recovery Team for Commercial Crew Transportation System (CCTS) Crew Module at White Sands Missile Range, NM and Dugway Proving Grounds UT. Upon landing, responsible for initial vehicle pyrotechnic assessment, grounding, stabilization, and parachute recovery. Certified and trained to perform recovery operations in Level B Hazmat gear including SCBA (Self Contained Breathing Apparatus).

Commercial Crew Transportation System (CCTS) Parachute Qualification Testing (White Sands Missile Range, NM) – Lead assembly, integration, and checkout of full scale crew module test article ordnance and avionics systems in preparation for drop testing. Prepared test procedures and lead hazardous ordnance installations, final vehicle system checkouts, and day of test final vehicle power up and arming operations. Performed six successful integrations and tests over a three year periodPyrotechnic Testing (Commercial Crew Transportation System CCTS) – Lead test conductor for all full-scale vehicle separation shock qualification and development tests. Led installation and firing system initiation of ordnance systems for the collection of dynamic shock and video data. Led setup and capture of real time and high-speed video (Phantom Systems) during all test events. Systems tested:• Parachute Deployments (Mortars and Gas Generators)• Heat Shield Jettisons (Separation Nuts, Separation Bolts)• Service Module Jettison (Separation Bolts)• Service Module to Launch Vehicle Separation (Frangible Joint)• Aero Skirt Jettison (Separation Nuts, Lanyard Pull Initiators, FCDC, TLX)• Aero Skirt Abort Doors (Linear Shaped Charges and Separation Nuts)• NASA Docking System Contingency Release (FCDC, Pyrotechnic Hooks)

Upward Falling Payload (UFP) Launch Test Conductor (Mojave CA, FAR Site) – Test conductor for a series of sub scale launch vehicle test launches. Tests were developmental in nature and involved launching vehicles from tubes to investigate tube pressure characteristics and vehicle performance. Final test launched a customer provided 10-foot long 1300 lbf thrust vehicle to 8000 feet altitude. Prepared set up and launch procedures, coordinated and designed relay control system and interface harnessing for launch vehicle. Supervised final vehicle electrical connections and checkouts. Acted as launch conductor controlling final countdown and launch activities. X-51 Hypersonic Vehicle Ethylene Blowdown Testing and Servicing (Huntington Beach and Edwards AFB CA) Test conductor for a series of propulsion system ethylene blowdown development tests. Tests validated vehicle ethylene ignition system and associated GSE. Testing involved filling and pressurizing vehicle tank with ethylene to 3500 psig followed by rapid depressurization blowdown to simulate flight ignition conditions. Testing also served as a pathfinder to develop test procedures later used for flight operations at Edwards AFB.

Test, installation, and checkout of ordnance devices for various satellite programs. Frequent use of electrical test equipment including igniter circuit testers, megohmmeters, oscilloscopes and electrical ground support (EGSE) test sets. Prepared detailed test procedures and checklists based upon program requirements, military standards (MIL-STD), and Air Force Range Safety (EWR-127) requirements. Supervised checkout and installation of devices during launch integration at Cape Canaveral, Florida and subcontractor facilities (Lockheed Martin – Sunnyvale CA).

Delta II Launch Support Engineer - Member of travel team to launch site in support of final launch and countdown activities and anomaly resolutions. Included on console engineering support during launch countdown reporting to vehicle systems engineer (VSE). Prepared and presented briefing charts to senior level management and customers (USAF and NASA) at various launch reviews (Pre-Ship, Pre-Vehicle on Stand, and Flight Readiness). Topics covered status and integration issues of vehicle Ordnance, Hydraulics, and Separation Systems.Component RE (Flight Termination Shaped Charges and Booster Separation Rocket Motors) - Responsible for ensuring vendor component production, acceptance testing, and launch vehicle installation complied with all system requirements. Coordinated resolution of technical issues arising during component production and flight installation Reviewed and approved supplier production documents and test reports to ensure compliance with component specifications. Provided oversight to component thermal cycle, random vibration, shock, leak, radiographic inspection and functional testing at supplier facilities and test labs.

Pyrotechnic Separation Shock Testing (Various Programs) – Lead test conductor for numerous full-scale separation shock tests of various Boeing vehicles including Delta III & IV Launch Vehicles and Ground Based Mid-Course Defense (GMD) Vehicle. Responsible for installing and initiating ordnance sub systems for the collection of dynamic shock and video data. Worked closely with dynamics and structures engineers and technicians to prepare test articles for testing. Systems tested:• Payload Fairing Separation (Separation Nuts and Linear Explosive Thrust Joint)• Stage Separation (Frangible Joint and Pyro-valves)• Solid Motor Jettison (Frangible Nut, Ordnance Thrusters, and FCDC)• Hold Down and Release System (Frangible Nut and FCDC)• Payload Release System (Clampband, Bolt Cutters)Thermal Vacuum Testing (Various Programs) – Test conductor for many thermal vacuum tests of various aerospace components. Testing occurred in large scale vacuum chambers with recirculating cryogenic shrouds using liquid nitrogen (LN2). Knowledge of cryogenic systems, vacuum systems, and test instrumentation.

Preparation of construction design documents for numerous large and small-scale mechanical facility rehabilitation projects. Rehabilitations involved Heating, Ventilation, and Air Conditioning (HVAC) Systems at various commercial and government facilities. Performed field investigations, design calculations, equipment selection, specification and cost estimate preparation, and review of equipment submittals to insure compliance with project specifications. Performed contractor oversight during construction activities. Projects included replacement of chillers, direct expansion compressors, coils, evaporators, boilers, pumps, fans, ductwork, airflow controls, and thermostats.