Designed 10+ custom power supply enclosures for defense contractors while balancing strength, cooling, weight, and volume requirements. Communicated directly with customers to review mechanical design progress, compliance, and milestones in weekly meetings and in major design reviews as the lead mechanical engineer for each project. Developed vibration and thermal profiles and procedures for HALT/HASS testing of a custom power supply worth over $35 million annually. Derived profiles based on benchmarks from prior testing and iterative experiments. Presented test data and profiles to end customer for review and approval. Created finite element models (FEM) of custom power supplies for use in structural dynamics (modal, shock & vibration) and thermal finite element analysis (FEA) in ANSYS. Used FEA to verify design compliance with customer requirements for part strength, fatigue life, & component thermal derating. Correlated FEA results with empirical test data from prototype units and relevant hand calculations from Steinberg, Blevins, Niu, etc. Designed test fixtures & procedures for mechanical & thermal surveys for test data collection. Revamped HDL's drawing creation process to more closely link 2D drawings with their master 3D models, thereby eliminating typographical errors and minimizing drawing creation time. New process reduced drawing creation time by an average of 30% per drawing.Resolved 100+ component and product nonconformities as a member of HDL's Material Review Board. Determined root causes and appropriate corrective actions to prevent repeat nonconformities.Mentored junior mechanical engineer and interns. Hired, assigned tasks, provided support, and reviewed work for junior team members, which enabled the successful creation and implementation of various fixtures which reduced touch time by over 90% and opportunities for human error and injury by 100% for over 1,200 units annually.

Designed a patent pending custom flat spring to hold various rectangular optics to their mounts for use in laser assembly. Utilized SolidWorks FEA to conduct design study to find optimal balance of FOS and spring deflection. Designed test fixture to validate FEA results and assumptions upon receipt of spring prototypes. Communicated with vendors to coordinate quoting and purchasing. New design reduced optic mount material and labor costs by 38%.Adapted fixed collimator optic mount to include height adjustment features. Height of all optics can now be individually adjusted without affecting other degrees of freedom, allowing for increased control of the laser's path. Utilized GD&T to control the mount assembly's position within parent assembly and the optics' interaction with the assembly's laser.Created custom jigs to hold bearing pads in place on parts for epoxy curing process. Jigs could hold numerous pads from multiple angles, decreasing the curing time by 50%. Executed Engineering Change Orders (ECO) through Omnify, submitting new revisions of SolidWorks drawings and bills of materials to get approved for production.

Supported R&D project to modify high temperature pneumatic side action grips. Conducted research and testing to solve high temperature lubrication issue. Created a test specification and assembly instructions for future builds.Designed custom fixtures in SolidWorks and assembled by hand to conform to customer specs and Instron safety standards.Identified and evaluated critical assembly components using SolidWorks FEA. Utilized GD&T callouts to ensure compatibility between critical assembly components.Managed 10 custom projects/month. Completed over 30 quotations and created over 20 manufacturing and installation drawings. Responsible for quotation, design, manufacturing, assembly, testing, and delivery to end customers.Solved corrosion issue with submersible pneumatic grips. Collaborated with other engineers to develop cost effective changes to preexisting design.Coordinated with manufacturing and engineering teams to determine root causes of issues and their solutions. Resolved over 20 different manufacturing issues with various custom projects.

Created designs for jigs to be used by surgeons in knee replacement surgeries using SolidWorks and proprietary CAD software.Reviewed designs of other engineers and collaborated with them to optimize functionality and fix errors; recommended design changes based on case-by-case evaluation of the functionality of each jig to determine if it met the design intention.Assessed assemblies of implants and jigs in SolidWorks and amended them as needed to ensure proper 3D printing.

Created part files/drawings using SolidWorks for existing machine components so that CNC machine operators could recreate the parts in the future.Collaborated with TSD’s engineers to create a new size of tooling for paper punches. Identified new components and ascertained correct measurements and parameters for each.Designed correctly scaled templates for company part drawings

Disassembled, cleaned, and reassembled machine moldsAssisted with the maintenance and operation of CNC lathes and millsCreated drawings of parts in SolidWorks.