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 dependance on mined materials from other countries. This is currently the largest lithium-ion battery recycling plant in North America. Ascend is building a 1 million square foot recycling plant in Kentucky.• 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 batteries, ranging in size from 1 to 850 kg, have been safely discharged during production operations.• Three patent applications have been filed for innovations employed in battery discharge systems.

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 company with $603M of sales for 2020 with customers including UPS, FedEx and Amazon. My team’s accomplishments included:• Introduced a new tandem magnetic pallet speed controller that handles loads from 75 to 3000 lbs., an industry first that led to a large $23M conveyor system order that was 43% greater than our total 2020 sales for this product line.• Implemented an automated manufacturing system for the roller flow conveyor product line using two robots, CNC saw, press and conveyors. The system has been in use for two years and saves 325k$ of labor annually and has an IRR of 60%.• 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 US airports.• 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.• Created automated workflow for conveyor projects, design changes and product testing using Microsoft Automate and SharePoint to track the status of hundreds of projects and automatically email stakeholders when their attention is needed.• Developed design automation tools using Autodesk AutoLISP to update the design and create drawings for sorter modules of varying lengths in five minutes, a task that previously took one week when done manually. • Leader in utilizing Microsoft Teams and OneNote to manage more than 100 projects with global stakeholders.

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 lithium-ion batteries and safety operate at temperatures up to 150 C (300 F). Applications include medical, electronics, defense and electric vehicle markets.• 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 electrolytes.• Manage process improvements and maintenance for research lab containing 7 sputtering systems, 1 CVD chamber, 5 glove boxes, 10 tube furnaces, 2 hot presses, SEM, XRD, XPS instruments, 3 clean rooms, 200 channel Maccor battery tester, YAG micromachining laser and Haas VF3 CNC milling machine.• Implemented QA system with IQ, OQ, SOP, FMEA and MBR documents for equipment validation and process control. • Setup contract with Institute for Matter and Systems (IMS) at Georgia Tech to use $400M of semiconductor fabrication and material characterization equipment to accelerate battery product development.

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 array of 50um wide heating filaments to create pores in the skin that allow a wider range of medicines, including insulin and fentanyl, to be delivered transdermally. • 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 resulting in 1200 data points that were analyzed using Minitab statistical process control program to calculate Cp and Cpk process capability indexes to prove the product would function as intended.• Improved yield of thin insulin film manufacturing process by 5-fold by utilizing a proven film casting technique from the printing industry. • Created quality documents including development reports, process capability metrics, SOPs, IQs, OQs, and calibrations for pilot manufacturing operation to meet FDA GMP requirements.• Installed vaults and security systems that passed DEA inspections for hydromorphone, a Schedule II narcotic.

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 fiber optic telecommunications. The design incorporated several innovative features including miniature free space optics, integrated multiplexing and a hybrid MEMS mirror assembly with integrated ASICs for mirror position control. Movaz was a fast-moving startup that raised $120M in venture capital and has acquired by ADVA Optical Networking. • 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. Functioning prototypes convinced competitor to pay a $10M fee to license this design for a niche market.• 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.

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 the deposition rate by 80x and eliminated substrate wrinkling that created uniformity problems during intense 3-month pilot production development effort resulting in patent US 6869484B2. • 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 controls for motion and process control. • 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 piping, compressed air, HVAC, machine shop, flammables storage and two 4000 sq. ft. clean rooms.• 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 superior paint stripping process feasible, resulting in a $5M contract from the US Air Force to implement these innovations in production. • 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 strip rate, improved quality and 94% uptime. • 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.• Programmed an Adept Technology machine vision system using Visionware to locate and determine the diameter of fastener heads in F-15 wings for a robotic system to replace wing panels.

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 process to manufacture ceiling suspension systems. Each of 7 lines produced 1 part per second, totaling 240,000 lbs. per day of production or $50 million of annual revenue. Transformed a troubled startup plant to world class lean manufacturing by implementing Six Sigma quality improvement program that greatly improved safety, quality, productivity and employee relations. • 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 supervisor are responsible for product quality and perform 20 written hourly checks.• 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 products and declining volume.• 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 in each installation. 15 variants of the design were deployed in 3 plants.• Reduced number of accidents from 31 to 9 over 3 year period by conducting Dupont's STOP safety training program to eliminate unsafe acts.

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.