Design and development of HVAC systems optimized for performance and weight to be utilized in electric and hybrid vehicles. Created complex assemblies and molded components using parametric models created in Siemens NX CAD software. Provided molding feasibility assessment to insure efficient tooling and robust molding processes. Worked with global teams in U.K, Japan, China and Mexico.

Design of production and prototype blow molds and related tooling. Supported all engineering needs and worked closely with the tool shop to produce the highest quality deliverables possible. Created 3D designs of single and multi-cavity extrusion blow molds in SOLIDWORKS. Created 2D drawing allowing detailed designs to be used to manufacture components and assemble tools and machinery. Designed related trim and transfer tooling required to trim, finish label and package final molded products.

In May of 2018 Grammer AG aquired Toledo Molding and Die to expand its North American footprint and diversify its manufacturing and product offering. My role remained primarily the same as before acquisition.

Designed and developed automotive HVAC systems for Ford, General Motors, Fiat Chrysler, Nissan, Honda, Mazda. Collaborated with customers, integrators, suppliers, and internal engineering teams to produce plastic-molded components and sub-assemblies. Managed program timelines, overseeing testing, APQP, PPAP, FMEA, and delivery. Liaised with OEM engineering, supplier engineering, and manufacturing to manage design and packaging issues and optimize deliverables. Coordinated tooling feasibility assessments and design/data releases. Utilized Siemens Teamcenter PLM and proprietary systems to validate and publish completed deliverables.

Engineered and designed automotive interior products, including instrument panels, door panels, consoles, and audio trim. Coordinated, designed, and implemented current model changes for Jeep Wrangler cockpit program. Handled Engineering Change Control (ECN’s), cost controls, and quality improvements under strict deadlines and coordination to insure uninterrupted production of vehicles. Managed design release processes and data management within Fiat Chrysler system while communicating with Release Analysts and customer Engineering. Provided efficiencies and value given this is often handled by the customers themselves. Transitioned processes from CATIA v5 and Virtual Product Modeling to Unigraphics NX and Teamcenter Engineering during FCA software migration. Successfully designed and released lighting and styling changes to Jeep Wrangler consoles and instrument panels that required consideration of existing tooling and processes.

Implemented corporate-wide Product Lifecycle Management (PLM) System. Consolidated product design, analysis, tooling, and project management data and linked it in relational organization, leveraging understanding of each department's needs and promoting cultural change in methods of storing and exchange of information. Also tasked with design responsibilities. Established standards and procedures for management of data and critical product information from concept through delivery. Integrated CAD systems (Unigraphics NX and CATIA v5) and migrated legacy data, including complex system of reuse and interchangeability, relating customer designs to preform designs and blow mold tooling. Trained employees in software and corporate processes related to PLM. Designed consumer products and related tooling for extrusion blow molding. Reviewed and validated all PTI preform, preform tooling, product, container and bottle designs ensuring accuracy and completeness.

Designed and packaged climate systems for Dodge Ram; Nissan Quest; and Ford Expedition, Navigator, and F-series pickup. Collaborated with vehicle program teams on-site at OEM facilities. Built strong customer relationships while attending daily meetings, build events and reviewing studio models. Integrated each system with vehicle package while considering fluid dynamics optimized for performance vs. value. Completed comprehensive design studies and supported package reviews, pre-production build events, and open-issue meetings with supplier teams and customers, resolving design conflicts and producing functional systems. Supervised multiple contract designers; guided design direction and validated deliverables.

Designed injection and blow molds used for the manufacture of thermoplastic components and related check fixtures. Molds were often multi-cavity and family in layout and required extensive parting-line development. Molds included moving actions including slides and lifters to release undercuts and create complex features. Effort was always made to optimize draw direction and part design to reduce costs, simplify manufacture, reduce cycle times and improve quality. Utilized mold filling analysis to determine fill and gating and designed for hot-runner systems when applicable.