Dr Christopher Micallef Email & Phone Number

Coventry, Gb

At WMG, an engineering research department of the University of Warwick (ranked in the top 10 in the UK and top 100 globally), I led the design and development of a novel track system within the Coventry City Council’s Very-Light-Rail programme. This collaborative R&D effort involves the UK government, industry, and academia, aimed at developing a new-segment cost-effective light rail urban transport system.• Served as the technical lead responsible for the development from first principles of a bespoke novel track system, from requirements definition, concept development, and detailed design leading to deployment-ready detailed specification production.• Secured international patents (pending) covering key structural sub-systems and installation methodology of the track.• Integrated novel sub-systems, materials, and manufacturing techniques into the design (including testing to use out of standard-spec.• Designed and executed the strategic innovation programme for delivering the project, including the procurement of outsourced specialist team services and systems, with a budget of over £3 million. Established project governance structure, managed stakeholder relationships, and oversaw risk and issue management.• Successfully produced prototypes and executed two pilot testing installations of the novel track system based on a system technology readiness level (TRL) maturity development program I created. This was critically important in securing an additional £70 million of funding to be awarded, allowing for a full-scale technology verification and validation program to be delivered.• Managed and led various cross-functional technical delivery teams based in different countries and organizations. In addition, led the engagement with over 50 external companies supplying materials, sub-systems, testing equipment, and/or expert consultancy.• Disseminated knowledge through lecturing and numerous presentations to stakeholders and at conferences.

Coventry, United Kingdom

Coventry, United Kingdom

As a doctoral researcher sponsored by Alexander Dennis Ltd. (ADL), the UK's largest bus manufacturer, I contributed significantly to the development of lightweighting strategies and solutions for ADL's bus designs.• Formulated a comprehensive lightweighting strategy proposal after conducting a systematic study, resulting in a 400kg reduction in weight of the E400 double-deck bus. This enabled ADL to achieve a subsidy-backed "low-emission bus" certification.• Conceptualized and developed a novel and holistic redesign of the upper deck roof structure, resulting in a significant 40% reduction in the weight of the sub-system, and enabling the potential of further weight reduction of the entire bus structure.• Defined and led the development of prototypes, forming partnerships with specialist suppliers. I also designed and conducted performance verification testing, assessing the manufacturability of the proposed concept at scale.• Conducted research on constituent sub-systems such as polycarbonate glazing and composite braided structures, which helped secure £1.5 million in research grants. The outputs of these grants won international awards, highlighting the impact of the research.

Malta

At International Meats Ltd., a meat-product manufacturing startup that represents Inalca spa (Gruppo Cremonini, a European leader in the meat and food industry), I served as the Engineering Manager, overseeing the technical aspects of the company's operations. With a focus on end-to-end product development, manufacturing systems, quality assurance, and packaging design, I played a critical role in growing the company from a start-up with 6 employees to a stable organization employing around 40 people across four establishments.• Created and executed a six-year technology investment strategy that facilitated company growth and expansion, including targeting export B2B opportunities in Libya, Italy, and Sweden.• Directly managed end-to-end product development including manufacturing systems, quality assurance, and packaging design.• Led the design, construction, and commissioning of a new 2000m2 production factory and all product manufacturing lines to meet an exponentially increasing demand from the Libyan market. I also oversaw the development of three retail outlets, each approximately 300m2 in size, to support the expansion of the company's B2C market.• Collaborated with cross-functional teams, including marketing, accounting, auditing, and legal, to ensure HACCP and legal compliance and drive business growth.

United Kingdom

During my tenure at Airbus' world-class center for the design and manufacture of aircraft wings in Bristol, I worked as a member of the fuel system design team for the A350WXB program, which involved designing innovative subsystems for the aircraft’s wings. • Achieved Airbus CATIA V5 design certification, enabling me to produce 3D models and issue the relevant 2D manufacturing drawings of fuel diffusers specifically adopted for use within the new composite skin wing.• Developed an automated fuel-level puddle analysis tool that reduced the previously required analysis time by approximately 70%.• Contributed to the creation of requirement specifications for the procurement of a novel lightweight composite fuel pipe.

Malta

ST Microelectronics, a leading semiconductor chip manufacturer in Europe, employed me as a process engineer at their Maltese plant. In this role, I had technical ownership of a specific manufacturing stage for chips utilized by high-profile clients including Nokia and Nintendo.• Conducted a manufacturing process failure mode and effect analysis (FMEA) study and designed a six-sigma-based quality control methodology, resulting in an increase in the manufacturing process yield of a high-cost and volume manufacturing line from 95% to 99.8% within 6 months. Also, prepared and delivered the associated training program to the technician and operator teams.• Managed the buy-out process for a £3m+ contract for the line’s manufacturing equipment.

Malta

Over the course of six years, I gained experience in various roles within BBQ Centre Ltd., a company that owned a chain of premium steakhouses and a food processing plant. Starting as a waiter and barman, I worked my way up to become a headwaiter, and eventually took on positions as a kitchen and stores operations manager and a manufacturing plant engineer.

Engineering Doctorate [Engd], Eng.D. International - System Design And Development

Research of Lightweighting techniques & Design Optimization,

Diploma In Leadership And Management, Business Administration And Management, General

Project, Programme And Portfolio Management, Project Management, Pg Award + Distinction

Postgraduate Award: Teaching And Learning In Higher Education, Higher Education/Higher Education Administration

Msc. Aerospace Vehicle Design, Aerospace, Aeronautical And Astronautical Engineering, Distinction

B.Eng (Hons.), Mechanical Engineering, 1St Class Honours