Dennis Malone Email & Phone Number

Wixom, Michigan, United States

Michigan, United States

Commercial HVAC, HVAC-D, and Natatorium design, development and program management.

Wixom, Michigan, United States

Senior Project Engineer for the W4CC and W750 platforms.

Livonia, Michigan

• Developed new customer-centric solutions for global product lines in the automotive and aerospace sectors.
• Optimized adhesive and film application processes, including robotic automation and fixturing for repeatability.
• Worked developing automation and robotic tape application head using nesting and UR Cobot for increased accuracy and production volume increase.
• Conceptualized development of prototype creation methods based on customer requirements.
• Devised innovative material and bonding solutions to create thermal barriers between lithium-ion cells and passenger compartment.
• Successfully participated in ISO 9001 and IATF 16949 audits, achieving a 100% success rate over a span of 5 years.

Warren, Michigan

• Made use of solid parametric and non-parametric interior models derived from styling data to develop instrument panels and console components.
• Introduced innovative product designs to optimize attaching mechanisms, dimensional controls, and F.E.A. performance.
• Collaborated closely with cross-functional teams to guarantee adherence to all FMVSS and homologation regulations.

Digital consulting of enhanced vehicle model creation for digital inspection.

Farmington Hills, Michigan, United States

• Implemented the design and project management of a Powerwall digital evaluation space for advanced digital perceived quality (PQ) testing.
• Designed and developed a comprehensive digital and physical vehicle testing method to assess perceived quality target achievement against benchmark competitors during digital design phase before tooling kickoff.
• Supervised a team of internal and external local and international resources for digital model creation.
• Pioneered innovative digital tools resulting in a significant cost savings of $2.5M in tooling changes per vehicle.
• Created new workflow processes bringing digital model creation from 1400 hours to 140 hours, fine-tuned this process to a final achievement of 110 hours allowing for a substantial labor reduction and allowing the.

Farmington Hills, Michigan, United States

• Evaluated first concept styling department models from Go with Three  Go with One stages guiding styling department designs into good HMI ergonomics.
• Directed the design and project management of motion capture laboratory, using motion capture and virtual reality in use case scenarios, loading scenarios including to detect true human motion.
• Incorporated new VR/AR technologies to evaluate visibility areas including pedestrian collision areas and A-Pillar obstruction.
• Established new ingress/egress targets for knee and head form movement during ingress/egress significantly increasing customer satisfaction.
• Created new guidelines for loading and unloading of removable seats monitoring lumbar load forces for initiative-taking injury prevention.
• Updated head clearances for hatchback and trunk usage to prevent head contact during operation.

Farmington Hills, Michigan, United States

• Led initial packaging and design feasibility of concept styling models to ensure carry over and new components could be packaged withing the design at Go with 3 stages.
• Evaluated glare, reflection, and HVAC targeting for compliance of internal and FMVSS requirements for windshield, navigation screen, instrument cluster lens, side glass and rear glass.
• Created primary sections for evaluation and signoff including through wheel visibility for instrument cluster.
• Redesigned 350Z center pods to correct lens glare in initial design from NTC-J.
• Corrected Titan back glass reflection issue during minor model year change using new physics-based software (Optis) I discovered, eliminating reflection from back glass in rear view mirror.
• Designed new center shifter area on the Quest to correct HVAC and audio controls being obscured by shifter in current product.

Alien Park, Michigan

Oversaw interior CAD projects which included assembly management projects, packaging, layout, and injection molding part design Maintained a significant knowledge of CAD related best practices, ensured designs adhered to technical specifications, and utilized various CAD software systems

Detroit, Michigan, United States

Trained on truck, trailer, rail, container ship, cold plate technology. 440v-480v and refrigerant certification for all CFC, HCFC and Isometric blends

Apprenticeship during MIAT classes.