David Phillips, P.E. Email & Phone Number

Phoenix, AZ, US

Conceptualize and develop electronics packaging for commercial, industrial and Mil-Spec environments. Simplify and cost reduce designs with Design for Manufacturability/Assembly (DFMA) techniques. Perform engineering analyses and incorporate results for thermal management, vibration control and shock mitigation.

Charlotte, North Carolina, US

Principal Reliability Engineer (Contract)Lead efforts to define and perform HALT (Highly Accelerated Life Test) Testing on commercial avionics products. Created simulated integrated system environment in which individual component HALT testing was performed. Utilize HALT results to tailor effective HASS (Highly Accelerated Stress Screen) production.

Charlotte, North Carolina, US

Principal Mechanical Engineer (Contract)Lead efforts to define and perform HALT (Highly Accelerated Life Test) Testing on commercial avionics products. Created simulated integrated system environment in which individual component HALT testing was performed. Utilize HALT results to tailor effective HASS (Highly Accelerated Stress Screen) production avionics.

Chandler, Arizona, US

Developed 2nd generation packaging to reduce total light engine volume from 4.3 CC to 2.0 CC. Highly collaborative design process working with laser physicists, optical, electrical and liquid crystal (LCoS) display engineers to integrate all components into a 4.7 mm tall embedded pico-projector with 30 – 60 lumens output.

• Propulsion Engineering: Product Point of Contact (POC) for Frangible Rails, Pyro Valves; responsible for conducting Service Life Extension (SLE) testing and documenting results. Reviewed and evaluated.
• Successfully executed shock & random vibe tests on a live thermal battery with Electrical Engineering monitoring output; tests covered gaps in vendor’s qualification, allowing batteries to be deemed flight worthy.

East Aurora, NY, US

• Electronics packaging design of flight control system components for controlling primary flight surfaces on the F-35 Joint Strike Fighter. Authored procedure for Highly Accelerated Life Test (HALT), then generated.
• Designed packaging of control avionics for primary flight control surface actuators on F-35 JSF. Verified new design with ANSYS™ finite element analysis (FEA) & computational fluid dynamics (CFD)
• Collaborated with Systems Engineers to integrate components into F-35 Flight Control Bay
• Reduced avionics chassis cost by 8% through refined corrosion control requirements
• Designed fixture to simultaneously solder eight insulated-gate-bipolar-transistors (IGBTs) to PWB and common heatsink to resolve both thermal run away and lead shear due to tolerance stack up.

• Led electronics packaging design of rocket avionics systems including thrust vector controllers, IMS and GPS guidance components, and flight termination subsystems. Authored Acceptance Test / Qualification Test.
• Conceived and developed innovative mechanical design of Electronic Safe & Arm device; part of US Patent # 9297627. Distilled physical and environmental requirements of several programs into one common design and.
• Directed successful severe environment qualification and acceptance testing of critical UHF antenna. Created source control drawings, designed test fixture, and wrote test procedures for dynamic & thermal environments

• Designed high density, high precision test and burn-in sockets for the Semiconductor industry. Sockets with up to 4000 pins on a 0.4 mm pitch were reliably designed for 50,000 cycles. Coordinated fabrication with China.
• Created and developed simplified design of very hi-density test socket for hi-power processors.
• Initiated and drove transition of prototype design to full scale production ramp in Chinese facility.

• Spearheaded development of LCD and LCoS displays for consumer, medical and automotive markets through collaboration with marketing, industrial and electrical engineering, key vendors and rapid prototyping shops..
• Designed lightest, thinnest injection molded Tablet PC (WebPad™) on the market at that time.
• Applied Design for Manufacturability/ Assembly methodologies to simplify prototype design; decreased part count by 70%, assembly time by 80% and weight by 30% in meeting size/weight envelope and cost targets.

• Developed Telcordia compliant telecommunications equipment for large scale high speed internet deployment. Led rack and chassis thermal management systems redesign for cooling patented Optical FDM multiplexing.
• Orchestrated extensive empirical measurements with CFD analysis to characterize severe overheating of rack; discovered serious air recirculation due to poor fan tray design, insufficient high power component heat sinks.
• Achieved over 200% airflow increase and reduced component operating temperatures up to 35 °C with fan tray internal redesign and repositioning and adding innovative circular finned heat sinks to high power components.

• Established and led the Mechanical Engineering function at a high tech start-up. Specified engineering tools, authored design/documentation standards and procedures. Recruited, hired and mentored mechanical staff..
• Designed innovative flex cable to route 80 control module signal & power lines through a doubly articulated joint, bending 90° in one axis and rotating ± 45° about a perpendicular axis, to a cell phone virtual display.

• Directed multi-discipline Concurrent Engineering teams in development of Mil-Spec airborne high density avionics systems. Led mechanical design of the Digital Communications Subsystem of a major defense program.Key.
• Achieved $1.7M (30%) mechanical engineering budget reduction, 5% better than the Design to Cost budget objective, for the Production phase of a major Mil-Spec high altitude airborne sig-int communications system
• Implemented rigorous Design for Manufacturability/ Assembly techniques to reduce 27 unique chassis’ to 3 standardized designs, cut documentation by 63%, assembly time by 40% and greatly reduce fabrication costs.

US

Bsme, Mechanical Engineering

Bachelor Of Science - Bs, Mechanical Engineering