Project Lead/Senior Mechanical Design Engineer
Sun Microsystems (Server Division)
Lead a team of engineers on an enclosure design for a storage product including power, packaging, EMC, safety, and cooling. Developed several high level design concepts and worked with program management, electrical engineers, marketing, service, safety and EMC engineers, and industrial design to refine the concepts into a product. Prepared and presented a product presentation to the Team using Power Point, before detailed design began, to ensure the Team understood the design, define the plan, and get Team consensus. Response to the presentation was phenomenal. Through the product website, posted reports, drawings and concepts, analysis, BOM’s, and other key information for the project. Made early mock-ups to perform space studies, initiate Team dialog and feedback, measure bulk airflow and local air velocities, and test and compare various cooling solutions to determine the best design. Performed preliminary thermal calculations to estimate component temperatures, determine high risk components and heat sink design requirements. Worked with suppliers to locate and specify cooling fans, heat sinks, and thermal interface material. Working with other cross-functional engineering groups, developed the design schedule and DVT test plan. Directed and oversaw the efforts of the mechanical engineers supporting the project via schedule reviews, dissemination of tasks, and reviewing proposed design concepts. Utilizing Pro/E, designed the enclosure including overall layout, detail sheet metal chassis design, physical PCB layouts and component placement (IDF process), cooling solution, power supply selection, EMI containment, connector selections, custom cable harnesses and cable management, status indicator placement, plastic light pipes, rack mounting strategy, and tolerance analysis.