- Primary responsible engineer and team lead for the upper stage of Astra’s Rocket 4 launch vehicle- Architected the system, mission profiles, and conops to satisfy performance, launch cadence, cost, and reliability requirements. Successfully presented the system designs to the Space Force during design reviews - Designed the upper stage propellant tank, feed lines, helium and nitrogen systems - Analyzed mechanical and thermofluid subsystems using NX NASTRAN, Simcenter AMESIM, testing and hand calcs - Negotiated requirements with engine supplier, satisfied customer needs where possible and required changes when not - Conducted ATP of multiple upper stage vehicles. Optimized data review tools to support high launch cadence - Performed mission control duties on the upper stage and engine team for multiple static fires and rocket launches - Designed payload plates around customer and vehicle needs. Integrated customer payloads in collaboration with NASA - Qualified welding and forming manufacturing methods. Created work instructions to ensure reliability

• Designed precision optical mechanical assemblies for $2M aerospace targeting and surveillance pod• Created cold plates, adjustable mounting brackets, harnessing and flex circuit boards for thermal imaging sensors • Performed ANSYS thermal and structural analysis, optimized results for mass efficiency• Created drawing and engineering change order release schedule to prioritize long lead, high-risk assemblies • Led product development meetings and collaborated on designs with international and domestic suppliers• Programmed volume creation and release schedule tools in NX to improve communication while reducing labor• Programmed interactive visual aids in Excel using Visual Studio which improved accuracy of manufactured product and reduced manufacturing time by 30%• Designed 3D printed conformal coating masking fixtures, reduced manufacturing labor hours by 75%• Established 3D printer material profiles to save material, improve reliability and increase dimensional accuracy• Investigated production, material, and design issues to determine root cause and execute corrective actions

• Designed manufacturing jigging for mission critical satellite components to ensure tight tolerances and repeatability.• Created drawings and performed GD&T tolerance analysis to verify interchangeability and express design intent• Updated qualification shock testing fixtures to validate flight hardware within a restricted budget and schedule

• Led design, manufacturing, assembly, and integration of the vehicle• Used Solidworks to design and FEA to analyze battery pack layout and structure• Managed team members and deadlines using Microsoft Project to ensure on time completion of the vehicle• Completed weekly technical reviews to verify compliance with competition rules and inspections• Optimized part design for available manufacturing processes• Designed suspension components and jigging to enhance vehicle performance and accurately locate parts• Fabricated parts using lathe, mill, CNC mill, MIG/TIG welding and 3D printing

• Developed and tracked concept readiness of low power ultrasonic sensors for autonomous uses• Performed failure mode effects analysis, established testing requirements and robust countermeasures• Composed function definition documentation and user experience scenarios for driverless operation.

• Maintained machine shop equipment to ensure safety of students and increase life of equipment.• Created machine shop training test and enforced safety procedures to reduce liability.

Created programs using VBA for estimating costs of welded brackets, tubes, and hoses.

Performed root cause analysis on failed parts and analyzed warranty data to reduce warranty costs.