Doug Danielson Email & Phone Number

Atlanta, GA, US

Westborough, Massachusetts, US

• Member of engineering team building 150ksf plant to produce lithium-ion battery cathode precursor (pCAM) and cathode active material (CAM) by using scrap electric vehicle batteries as the feed stock, which eliminates.
• Designed and built lithium-ion battery discharge system to safely deenergize cells, modules and packs prior to recycling. Energy is returned to the grid to reduce electricity use and carbon footprint. Thousands of EV.
• Three patent applications have been filed for innovations employed in battery discharge systems.

Sant'Antonino, CH, CH

• Directed 20 person engineering department of 150 ksf manufacturing plant that produces $80M of automated material handling equipment, including conveyors and sorters, for the American market. Interroll is a Swiss.
• Introduced a new tandem magnetic pallet speed controller that handles loads from 75 to 3000 lbs., an industry first that led to a large $23M conveyor system order that was 43% greater than our total 2020 sales for this.
• Implemented an automated manufacturing system for the roller flow conveyor product line using two robots, CNC saw, press and conveyors. The system has been in use for two years and saves 325k$ of labor annually and has.
• Built four prototype cabin baggage screening conveyor systems that required development of new adhesive bonding, stud welding, anodizing and glass fabrication processes. The TSA intends to buy 3000 systems for use in.
• Collaborated with French Center of Excellence design team to implement next generation of roller flow conveyor product that will provide a common worldwide platform that allows advanced features to be quickly introduced.
• Installed a Haas ST-40L CNC lathe that knurls brake tubes in one quarter the time of the prior system.

• Responsible for developing manufacturing processes and facility in startup firm developing solid-state lithium-metal batteries. Solid-state lithium-metal batteries have up to 3 times the energy density of conventional.
• Created new manufacturing processes to increase capacity and lower cost of solid-state lithium-ion batteries by replacing slow vacuum based deposition processes.
• Developed a micro battery (0.5x3x8mm) with six times the capacity of competing products, for a leading medical firm to use in a small embedded medical device.
• Created detailed commercial scale manufacturing cost models for business plans based on current lab processes and knowledge of high-volume manufacturing systems.
• Designed and machined shadow mask tooling system to allow efficient deposition of separator and anodes for solid state battery cells which increased yield from 30 to 80%. Machined tooling on in house Haas VF3 CNC mill.
• Designed hydraulic hot-pressing process using induction heated tungsten carbide tooling to allow fabrication of dense ceramic pellets at 1000C and 64kpsi in Argon filled glovebox for use in battery cathodes and.

• Directed the development of high volume manufacturing processes to produce an innovative transdermal drug delivery patch for use in clinical trials at startup firm that raised $45M over 3 year period. Patch uses a MEMS.
• Built out and maintained 68k square feet of lab and office space containing clean rooms, clinical suites, analytical labs, warehouse, offices and maintenance shop.
• Designed automated manufacturing equipment to produce transdermal patches utilizing a web converting machine, assembly robots, machine vision inspection system and a clean room.
• Designed an automated array functional testing system utilizing an infra-red machine vision camera to automatically test the filament array, an electrical component containing hundreds of tiny filaments.
• Conducted Design Verification Plan and Report (DVP&R) to validate robotic patch assembly system by using MicroVu machine vision dimensional inspection system to measure eight critical dimensions from each patch.
• Improved yield of thin insulin film manufacturing process by 5-fold by utilizing a proven film casting technique from the printing industry.

US

• Member of development team that created a MEMS mirror based all optical switch that provides 400x400 wavelength switching and an optical power meter that monitors 2000 wavelength channels simultaneously for use in.
• Created an industry first, miniaturized all optical switch in 15 months by using rapid prototyping techniques to spin new versions in 1 month vs. 6 months required by a large corporation that was the original supplier..
• Created 3d mechanical designs of the optical power meter, optical mounts for the optical switch and many test fixtures with Pro/ENGINEER. Designed tooling and processes to allow robotic assembly of MEMS mirror assembly.
• Setup optic test lab for assembly and testing of prototypes consisting of 10 workstations, a cleanroom, thermal and vibration test systems and material storage.

Lexington, Kentucky, US

• Responsible for engineering, facilities and safety of startup electronic materials development firm that graduated from the Advanced Technology Development Center at Georgia Tech and grew to 150 employees in 4 years.
• Saved thin film coatings firm’s most important product development contract to create an embedded resistor product with a $500M market potential for Shipley Corp. by developing a new deposition chamber that increased.
• Led team that designed and built 25 automated thin film deposition systems for applications in electronics and fuel cell manufacturing. Used Pro/Engineer for mechanical design and National Instruments/Labview based.
• Leader in $1.5M project to consolidate operations from five separate buildings into one renovated 150k sq. ft. building. Directed team that planned and constructed 100k sq. ft. lab space with power, flammable gas.
• Created department of 20 engineers and technicians to support material science research programs.

• Provided engineering services to four firms on a contract basis.
• Programmed semiconductor assembly robots using Adept Technology’s V+ robot programming language.
• Increased productivity of automated grid packaging system from 201 to 245 cartons per shift, a 20% increase.
• Supervised installation of 11 new pieces of equipment, including Fanuc welding robot, CNC laser cutters, presses and air compressors.

• Directed the redesign and programming of a robotic paint stripping system that used dry ice pellets to remove paint from F-15 fighter aircraft. Developed important process improvements that made a new, environmentally.
• Won a $5M contract from the US Air Force to upgrade a dry ice pellet robotic paint stripping system used for maintenance of F-15 fighter aircraft, due to process development work that demonstrated a 5 fold increase in.
• Programmed and stripped paint from six F-15 aircraft using robots and dry ice process, where the robots performed with an uptime of 94%. Each robot moved through.25 miles of paths to cover the aircraft’s surface.
• Supervised up to 10 engineers or technicians and interfaced with all levels of government and Air Force personnel. Effort included several months of 60 to 100 hour weeks to meet accelerated schedule.
• Received commendation from base commander for process development work that lead to a 5 fold increase in strip rate by using nitrogen cooling of blast air and smaller diameter pellets.
• Retrofitted new Adept Technology motion controllers to three large nine axis robots. Each robot required at least 1000 wires to be reterminated. Created wiring diagrams of retrofit to mil spec requirements.

Chicago, IL, US

• Responsible for 90 employees in the production, maintenance and engineering departments of 100,000 square foot, 120 employee, three shift metal forming factory. Plant used roll forming and punch presses in high speed.
• Managed $4.6M operations budget to generate a $225,000 favorable variance vs. prior year while plant produced revenues of $50M, despite increased changeovers, lower inventories, new products and declining volume.
• Reduced scrap from 3.8% to 1.8% over 3 year period, an annual saving of $500,000, by developing daily reports to make employees aware of scrap cost and equipment changes to improve reliability.
• Reduced value of customer product quality complaints from $100,000 to $25,000 over 3 years on sales of $50 million, which is a 5.86 sigma quality level. Implemented an inspection system where the operator and.
• Created $2.5M of documented, annual savings by establishing Kaizen or continuous improvement process to identify and implement hundreds of process improvements, despite increased changeovers, lower inventories, new.
• Received USG Chairman's Award for designing automated packaging systems that saves $1.5M of labor annually. Systems have been in three shift production use saving the labor of 9 employees or $270,000 of labor annually.

Bethesda, MD, US

• Developed new manufacturing methods in the construction of prototype, classified aircraft. Held TS/SCI clearance.
• Member of Integrated Product Team that built multiple copies of classified aircraft from concept to flying in 18 months. Gained experience in applying world class management, engineering and manufacturing methods.
• Designed and built error free tooling and lightweight composite aircraft parts using state of the art computer aided design and CNC machine tools. Skilled with IBM's CADAM and CATIA computer aided design systems.
• Supervised 10 union manufacturing research technicians during weeks of 12 hour graveyard and occasional 24 hour shifts to meet aggressive delivery schedule.

Bachelor Of Science, Mechanical Engineering

Master Of Science, Management