Responsible for managing all manufacturing and engineering operations. Designed new manufacturing and assembly methods to expand design options to achieve better aerodynamic performance. Supported several amateur racing teams with designs that doubled the vehicle performance with simple, durable, and cost effective parts; often at 50% the cost of competitors. Managed multiple design projects for the first debut of the company at SEMA; attracting international distribution orders.● Sole engineer responsible for all designs, CAD files, drawings, and sheet metal patterns for parts and mounting hardware. Evaluate new vehicle platforms to identify suitable mounting locations for support brackets. Factoring load paths, accessibility, manufacturing, and serviceability.● Provided technical direction for aerodynamics during the development phase of products to balance aesthetics and performance. MFR Engineering’s philosophy is to offer customers an aesthetically pleasing product but one that is also aerodynamically functional.● Review existing products, installation methods, and shop processes. Developed flexible design techniques that compressed the design and prototyping process from two weeks into one week.

Process Engineering/Manufacturing Engineering, Hot Forging● Worked with operators to implement lean manufacturing techniques, standardized tooling, to reduce process waste thru continuous improvement projects.● Replaced dated induction heating units with modern digitally controlled heaters. Newer units reduced heating time by 50%-75% and more evenly thru heating for all parts using saved heating profiles for each part number.● Conducted DoE studies to evaluate press tooling, punch and die design, forge lube, and coatings. Improved die life 100%, punch life by 5 times, and improved Process Capability PPK from ~.6 to 1.6.Manufacturing Engineering, CNC● Reviewed, approved, and tracked ECR’s for process and design changes. Revised manufacturing prints, reviewed GD&T, and revised work instructions for operators.● Worked with an interdisciplinary team to evaluate and track new product introduction(NPI) projects.● Lead project to develop a process for form drilling inner parts designs. Each batch of parts would have a unique inner bore requirement. Worked with tool suppliers to prototype a set of specifically sized pairs of drills and reamers that would drill the finished inner part profile instead of drilling and boring.● Worked with tooling providers to perform tool life studies for rough drilling Inconel 718. Selected a cost effective solution for a large multi-part fixture. This expanded capability aided in reducing the workload of gun drills.Data Analysis and Root Cause Analysis● Reviewed testing documents, test samples, and raw test data to investigate testing issues on the MTS testing platforms. Developed a more consistent and accurate testing method.● Collected and analyzed a large amount of testing, material properties, part size, and heat treatment data to build a statistical model for selecting a heat treating temperature to provide the proper shear strength for parts.

● Optimized a set of compression supports for the Dragon 2 heat shield using FEMAP and simple topology optimization to reduce system mass by 15%. Created sub-scale FEA models to evaluate localized stress on the composite heat shield laminate.● Eliminated a lengthy match-drilling assembly operation by designing a shear-carrying joint capable of handling the manufacturing tolerances of the composite panels. Developed and performed lab testing of the joint and composite laminates to verify joint strength and evaluate joint failure modes. Analyzed test data to provide statistical basis for joint strength.● Worked in conjunction with an Analysis Engineer to design sub-scale DoE corner-case tests. Documented and analyzed testing data to determine design stress limits and to correlate FEA models of the joint. This allowed for a more accurate modeling of stress critical areas to better predict design margins of the outer thermal protection panel structures.

• Lead team of 5 engineers to design and produce team’s first aerodynamics package. Responsible for CFD analysis in STAR-CCM+ and composite design path. Achieved desired mass goal of 20-lbs by implementing a mix of traditional wing construction methods with complex one-piece co-cured spar designs. Aero package reduced lap times by 3 seconds. • Lead structures analyst for vehicle. Performed finite element analysis for suspension, drivetrain, and chassis components. Implemented topology optimization for suspension and brake components to save 25% of mass by producing non-intuitive designs. • Lead the development for the team’s first two composite monocoque chassis. Responsible for composite and tooling design, manufacturing, and integration. Stressed engine design reduced chassis weight by 25-lbs while meeting torsional stiffness goals.

• Processed customer models to design tooling for manufacturing composite parts. • Updated manufacturing drawings for composite parts in Catia V5. • Designed manufacturing aid for layup technicians to assist in manufacturing of odd shaped parts.