Dillon Card Email & Phone Number

San Francisco, California, Us

- Scaling a multidisciplinary engineering team (mechanical, electrical, automation & controls, and manufacturing engineering) to deliver hardware and software solutions- Focusing on rapid expansion and delivery of verified carbon dioxide removal credits through custom biomass processing, pyrolysis production, bio oil injection, and bio char sales- Developing engineering technician and maintenance departments to support 24/7 production activity

San Francisco, California, Us

- Designed and optimized novel Carbon Dioxide Removal solutions using waste biomass feedstocks (specifically woody biomass from wildfire mitigation cuttings)- Founded a cross functional engineering and test team to conduct strategic operations support and design improvements of custom pyrolyzers - Developed rigorous factory and site acceptance procedures for commissioning of new pyrolyzer assets- Improved production system uptime by 3x using targeted reliability upgrades and maintenance campaigns based on issue landscape data

Louisville, Colorado, Us

- Maximized diversion and reuse of valuable commodities from landfill-bound material by deploying automated sortation products- Guided core engineering and operations teams to conceptualize, develop, and implement new technology to enable AI-controlled material recycling- Supported full MRF (material recovery facility) design and system commissioning to handle a high mix of recyclables and solid waste ranging from residential to commercial sources- Managed Engineering BOM validation + release for confirmed projects, while organizing internal production and procurement efforts for custom and off the shelf components - Performed system analysis for new business capture by generating line diagrams, mass flows, projected electrical demands, and budgetary equipment lists

Hawthorne, California, Us

- Led the Non-Destructive Evaluation (NDE) Operations org of 160+ employees across dynamic Build/Test/Launch sites in California, Texas, and Florida- Established robust and creative inspection approaches for new SpaceX development hardware (Raptor engines, Starship launch vehicle subassemblies) - Scoped capital expenditure forecasts and monitoring ongoing operational expenditures vs. monthly target budgets- Established Key Performance Indicators for each work center; drove accountability to quality targets via monthly reviews (PowerBI data visualizations)- Championed Root Cause and Corrective Action project to mitigate inspection escape risks and resolve organization-wide inefficiencies - Deployed new project management and employee feedback approaches using Atlassian platforms (Jira, Confluence) to increase response time to shop floor blockers and drive issue resolution accountability using task automation- Revamped employee recruiting, compensation, and career development strategies to promote robust quality principles and process improvement efforts in addition to NDE method certifications (+30% team growth using new approach)

Hawthorne, California, Us

- Led a company wide engineering R&D group to deliver innovative quality and reliability solutions to a diverse customer base across SpaceX- Actively collaborated with and project managed a distributed team of stakeholders across all build, test, and launch sites.Examples of project launches: - Torque Reliability: spearheaded adoption of Direct Current (DC) torque tools across all major assemblies; standardizing torque processes and employee skill development to reduce build escapes and risk- Composite Cure Profile Analysis: qualified software tool to eliminate ~90% of manual quality verifications on eligible parts via automated time series data analysis- Defect Mapping Software: developed custom, web-based application to facilitate location tracking of key defect data and enable efficient communication and inspections through initial build and multi-flight reuse

Hawthorne, California, Us

- Managed quality of Falcon 9 Mechanical Integration and Avionics work cell; set new non-conformance management process standards- Developed and validated >30 unique vehicle maintenance/refurbishment procedures with the goal of rapid launch vehicle reusability for East and West Coast missions to mitigate risk & variation- Collaborated with a cross site team to establish common procedures for standardization of vehicle build, test, launch, and maintenance

Hawthorne, California, Us

- Monitored non-conformance resolution for Falcon Propulsion and Avionics- Conducted first article build reviews for the Block 5 vehicle architecture with an emphasis on reusability and service life

Hawthorne, California, Us

- Supported production efforts in Vertical Barrel Integration, Friction Stir Welding, and Paint processes on Falcon 9 and Falcon Heavy launch vehicles - Developed and qualified new technique for Non Destructive Evaluation of structural health using advanced Eddy Current (ET) arrays- Reduced aggregate weld inspection time by ~60% (175 hours per full vehicle) while increasing flaw detection by 95% - Drove process improvement initiatives to increase build efficiency and conducted real time defect tracking

Bethesda, Md, Us

- Selected for the 2016 Vega Program through a competitive interview process- One of 20 participants selected out of 96 total applicants; 21% acceptance rate- Required the initiative to take responsibility of an additional 20% more work on top of current position - Goal: to investigate emerging additive manufacturing methods for applicability to the company- Tracked a 1 year program schedule and $87K R&D budget via Earned Value Management techniques, as well as compiled technical research findings - Interfaced with candidate suppliers for potential future procurement of the technology

Bethesda, Md, Us

- Worked as a Structural Analyst for the F-35 Program at Lockheed Martin Aeronautics Company- Conducted structural analysis on metallic substructure components as well as composite skins, control surfaces, and edges- Generated formal data and documentation to support test article modifications and in-field fleet repairs- Supported non-destructive evaluation (NDE) efforts and repair of manufacturing anomalies

Tempe, Az, Us

- Functioned as a Graduate Teaching Assistant for the Senior Design Course within the School for Engineering of Matter, Transport and Energy at ASU- Generated an updated curriculum designed to enhance participant learning while increasing efficiency and productivity- Created and presented weekly lecture sessions while managing deliverables for 120 enrolled students

Bethesda, Md, Us

- Worked as a Stress Analyst Intern with the F-35 Lightning II Program at Lockheed Martin Aeronautics- Aided in stress analysis activities on aircraft components such as the wing box, wing skins, nacelle, armament attachments, etc.- Completed supporting fastener analysis work on composite components

Tempe, Az, Us

Through the Fulton Undergraduate Research Initiative (FURI) program, undergraduate students are given the opportunity to conduct research alongside faculty and in turn gain valuable laboratory skills and professional research experience.

Tempe, Az, Us

- Aided during two mechanical engineering sections of the freshman course ASU 101 - Collected/graded homework, responded to student inquiries and emails- Supplemented course material for the students with personal input from past ASU experiences- Formulated discussion PowerPoints and conducted lectures

Tempe, Az, Us

- Developed proof of concept design for a contracted project for the US Navy- Conducted Pastran post processing and aided in Nastran stress analysis- Aided in structural analysis of developing LOX valve bodies and associated components for NASA

- Designed, tested, and analyzed system parts in the solar array product using SolidWorks- Created a complete product bill of materials including intelligent part numbering scheme- Integrated system B.O.M. utilizing Infor (ERP software) for production and efficient inventory control

Master Of Science (Ms), Mechanical Engineering

Bachelor Of Science In Engineering (Bse), Mechanical Engineering