Greg Forrester Email & Phone Number

Seattle, Wa, Us

Kent, Wa, Us

-Mechanical Engineer for New Glenn's second stage (GS2). -Component Engineer for the GS2 Auxiliary Power Unit (APU). -Created design, manufacturing, and test artifacts in support of the APU, Flow Control Valve (FCV), and Hydraulic Power Pack.-Led development and production APU manufacturing-Conducted APU and FCV development testing using Nitrogen (GN2), Hydrogen (GH2), and Helium (GHe). -Led FCV production manufacturing and acceptance testing (ATP)-Led Production Readiness Reviews (PRR) for the FCV and APU. -Designed Ground Support Equipment (GSE), including proof tools, for the APU.-Material Review Board (MRB) certified.

Kent, Wa, Us

• Responsible for all manufacturing of New Glenn’s first and second stage Hydraulic Systems, and second stage Mechanical Systems.• Hydraulics – Valves, Accumulators, COPVs, Reservoirs, and Manifolds. • Mechanical Systems – Auxiliary Power Unit (APU), Flow Control Valve, Structural Frame, and Hydraulic Powerpack• Created key manufacturing artifacts including work order instructions, tooling identification and procurement, deficiency reports/non-conformances, job hazard analyses, build time estimates, and make/buy plans.• Performed design for manufacturability reviews on 300+ component and assembly drawings. • Supported adjacent design teams such as New Glenn Structures, New Glenn Fluids, and New Shepard Hydraulics to achieve program milestones.• Contributed to company-wide process development and improvement initiatives. Implemented manufacturing demonstrators, control drawing standards, and make/buy tools.• Developed an on-boarding program and manufacturing resources for new employees in support of the team’s rapid growth. This includes a new hire checklist, manufacturing process flow, build and flow template, work order repository, and control drawing and torque trainings.

Patuxent River, Maryland, Us

Flight Controls and Subsystems Engineer, H-53• Provided manufacturing and production solutions in support of rework, repair, inspection, modification, acquisition, and continued airworthiness of all subsystems and flight control systems on the H-53 helicopter. • Developed engineering instructions to increase the efficiency of production and maintenance processes while reducing program costs. • Investigated and resolved complex technical problems encountered by fleet operators. • Reviewed failure data and implemented recommendations to improve operational safety, future performance, reliability, and reduce operating costs.• Performed engineering investigations on 75+ flight control and hydraulic components for the H-53 El Centro crash investigation. This involved component testing, disassembly, material analysis, and in-depth research on the flight controls, rotors, and hydraulic system requirements and capabilities. This investigation involved coordination and frequent briefing with logistics, the Naval Safety Center, and the Aircraft Mishap Board. • Performed stress analysis on aircraft components to establish damage limits and reduce scrap rates. When hand calculations could not sufficiently characterize the component, Finite Element Analysis (FEA) was conducted using CATIA V5 and ANSYS. • Created alternate flight controls rigging procedures which reduced aircraft downtime by 200+ hours and lowered maintenance time by 80%. • Determined critical characteristics, failure modes, and end effects for 100+ components.• Trained, tasked, assisted, and reviewed work of a summer intern. Environmental Control System (ECS) Engineer, F/A-18• Conducted engineering investigations on F/A-18 cabin pressurization valves, determined root cause of failures, implemented corrective actions, initiated risk mitigation practices, and developed final reports to express the findings.• Developed source data to correct maintenance, repair, and test procedures.