Senior Mechanical Engineer

Lead Electro-Mechanical Engineer; OSAM-1 On-orbit Servicing, Assembly, and Manufacturing Robot Arm plus Advanced Tool Drive System.Responsible Engineer for all flexible circuit design and manufacture for dual Robot Arms and Tool Drive System. Flex circuits are Mission-critical interconnection technology for 7-Axis Multi-Joint Robot Arm, plus 3-axis motion Camera Positioning Systems.

Electro-Mechanical Engineer, automated chip test equipment design using Solidworks. Teradyne Inc, N. Reading, MA - contract engineering role with Colonial Staffing Inc.

Senior Electro-Mechanical Design Engineer; creating state of the art Extreme Ultraviolet laser lithography scanners, used in microchip processor and memory manufacturingSystem architecture, vacuum grade components, flexible circuit board + interconnection design; clean room production support; test equipment design and production; additive manufacturing

Space Robotics Design Engineer. Created prototype and flight hardware for Dragonfly next-generation robotic arm and mechanism. Robots to be used on self-erecting satellites and on-orbit repair in geostationary earth orbit.Designed robotic mechanisms, zero-gravity simulating carriage-gantry, for earth-based demonstration of space robotsy. Designed specialized cables for controlling seven-actuator robotic arm.Created and 3D printed prototypes of space-flight models, for extreme temperature testing. Coordinated procurement, manufacturing and assembly of prototypes.

Designed actuator and wing control units for Sierra Nevada Corporation Dream Chaser® space shuttle. Created actuator controller 3D chassis assembly, integral cold-plate, and printed circuit board layout.Senior mechanical contributor on winning Dream Chaser® wing control unit proposal. Created 3D layout, translated customer specifications into a design compliance plan.Performed 3D modeling, detail design, and tolerance analysis on high-powered, liquid-cooled power controllers, with output up to 75 kilowatts; Desktop vibration and thermal analysis

Designed and upgraded aircraft cockpit flight instruments and flat-panel displays, for helicopters and small commercial aircraft, using Solidworks. Integrated and upgraded night-vision-capable LCD assemblies, printed circuit boards, flex circuits, into complete chassis assemblies.Performed 3D modeling and detail design of new and existing cockpit displays. Designed machined, injection-molded, and sheet-metal housings and brackets, using Solidworks tools. Introduced desktop vibration and thermal analysis tools to supplement full-scale testing.Coordinated design activities between worksites, designers, vendors, test facilities, manufacturing, software engineers, QA and management.

Contract design and self-directed Solidworks training with Dassault Systems, GoEngineer and Hawkridge Systems

• Coordinated successful upgrades to NASA’s Apollo-era 70-meter DSN ground antennas.• Conducted design reviews, interfaced directly JPL and DSN customers.• Developed task schedules and site installation plans.• Proposed, developed, implemented, tested and approved antenna subsystem upgrades.• Coordinated software/hardware upgrades to LabView-based data acquisition instrument.

• Designed airborne rotating synthetic aperture antenna, using Pro-Engineer and Pro-Cable tools.• Managed antenna interface control with a major industry partner, per contract requirements, in a collaborative 3D solid-model environment.• Coordinated thermal and vibration analysis complying with stringent flight environment and weight requirements.

General Dynamics Land Systems/Delco• Lead first unit production team for Comm System for US Army M1130 Stryker Command Vehicle.• Coordinated design/build activity at supplier and factory.• Aggressively resolved numerous vendor design and production problems, recovering vehicle production schedule.

Sr. Design Engineer, project leader for various JPL instrument design tasks, using CREO/Pro-Engineer, Labview, Excel