Postproduction sustaining engineering activities on the KC-46A and KC-135, large military tanker transport aircraft. Reviewed OEM responses to FAA Service Letters coordinating internal Air Force internal response to them. Reviewed new to the Air Force Component Maintenance Manuals for deficiencies and clarity. Documented clarity and deficiency issues and responded to them for the Air Force. Reviewed Discrepancy Reports and wrote engineering responses to them.

Design engineered an extensive environmental ducting modification to the forward section of the 787-9 Boeing large body aircraft using Catia V5 and Enovia. Provided structural engineering design changes to 767 fuselage frames to allow for monolithic machining thereby improving tolerance conditions during the build. Providing engineering design solutions to legacy design issues of 767 production aircraft working in IPT's.

Developed post production structural repairs and kit repair drawing for damaged F-22 Raptors using Catia V5.

•Performed aircraft engineering level review of a C-5 ITAR new vacuum lavatory on detail part drawings, assembly drawings and installations modeled by NX8.5 where views were transferred into a drawing format in AutoCAD 2014.•Brought the local site into awareness of the knowledge of tort liability of the inadequate handling of ITAR material saving the site an estimated $1.7 million in government fines and saved site employees potential from Federal prison for the offending personnel.•Coached non-design NX modelers in proper aircraft designs and aircraft mechanical processes for fabrication, assembly and installation methods.•Provided aircraft best practices knowledge that improved the overall installation assembly in terms of the mechanical structure and the system’s ability to withstand corrosive fluids and a corrosive environment.•Made employee suggestions to improve employee living standards near the site and provided a business algorithm to determine the best CAD system for future projects.•Data mined original equipment manufacturers installation processes for use in post production assembly and installation drawings.

•Modified engineering on aircraft interiors to improve detail fabrication, improve system functions, and to customize new designs based upon customer desires and certification requirements. Items engineered were ceilings, vent systems, partition panels, closets, plumbing systems for galleys, galley cabinetry, and oxygen system routing.•Catia V5 was used for solid modeling and digital mock ups which were in turn used to create datasets or drawings for engineering approval and certification approval. This information was stored and accessed for approval in SmarTeam. •Often for one shipset cases Autocad was used to create datasets or drawings and stored and accessed for approval in SmarTeam.•Investigations into problems pointed out by shop personal were made by reviews of the products, their assembly and installations with the aid and presence of shop personnel, their leadership and in some case aircraft customer representatives and customers to resolve problems in a safe, certifiable and otherwise acceptable engineering manner to all.•Facilitated the tracking and completion of new engineering in SmarTeam and engineering tracking meetings.

•Prepared training materials on PowerPoint for the 787 Overhead Stowage Bin interior commodities as to their scope of use for new management and engineers. •Conducted engineering testing on new part configurations to obtain abuse loading data and over design factors so that fittings and other components could be reduced thereby saving weight and cost associated detail fabrication and assembly saving about 20 pounds per aircraft on average and about $180,000 in manufacturing cost per aircraft•Investigated fitting material changes that potentially reduced weight and cost of Bin fittings after being giving the worst case loading of the various fittings and through iterative trial and error modeling using the Catia V5 Finite Element Modeling workbench saving about 8 pounds per aircraft and about $45,000 in machining cost per aircraft. Estimated weight saving, cost savings, and implementation cost for feasibility studies on PowerPoints to present to management.•Catia V5 models and datasets using Boeing approved Model Based Definition processes that were saved and approved in Enovia.•Conducted project engineering efforts on 3 process replacement materials that the EPA was in the act of making illegal to use by tracking material alternatives from vendors, and tracking, aiding and helping engineering in producibility trials, color trials, texture trials and flammability trials. Implemented plans and alternative risk reduction plans in the Boeing software program Boris that keep track of planned events and allow for up to 3 mitigation plans per each process. Informed and worked with managers up to the 5th level on the progress or lack of progress on each project. •Implemented bond testing for electrical standoffs when they were bonded to various Bin panels to obtain load strength values and document them in an engineering report format so that documentation existed to support assembly certification efforts.

•Dispositioned nonconforming details and assemblies for engineering on the 787 aircraft found in the final assembly line in most cases providing repair instructions for damage composite materials.•Trained Catia V5 modeling through coaching to liaison engineers.•Researched Catia V5 models and assembles sealing conventions to determine the scope of a potential sealing problems in aircraft production and documented on PowerPoints for management review and coordinated engineering MRB dispositions to keeping the aircraft production on track.•Investigated and facilitated alternative parts for engineering approval to use for part shortages.

Trained Catia V5 modeling through coaching to design engineers.

•Motivated and lead a group of domestic and foreign design engineers and checkers to modify the wings of a Boeing 767 to allow the installation of a winglet using Catia V5 metallic sold modeling modules using Geometric Tolerancing & Dimensioning per ANSI Y14.5M. •Represented Butler on the project to American Airlines, to the primary contractor, and vendors on structural design aspects using Catia V5 in modeling, in drawings and in a non-PDM DMU process. •Represented the engineering director when the director was absent. Coordinated early stages of tooling development with American Airlines and aided in its engineering design budget estimation.•Coached foreign mechanical designers on aircraft structural design and aircraft conventions to use Catia V5 surfacing and modeling modules efficiently for use in creating engineering production drawings from crude concept provided by Aviation Partners Boeing. •Coordinated stress analyst efforts and comments to junior engineers and back, as well as coordinated solid models to Indians in India using Internet transfer methods and back for the fast creation of engineering production drawings. •This effort also involved pre-ordering parts and material before the completion of the engineering bill of materials by estimation for long lead order items based on non-released preliminary engineering.

•Converted and modified Catia V4 crude conceptual models to release-able Catia V5 models and engineering production drawings for super first class seating pods for use on the 777 wide body aircraft. •Catia V5 models of sheet metal, machined, composite, and plastic parts were created using both simple model and advanced surfaces modules of Catia. These parts in turn were used in creating assemblies, installations and drawings in Catia V5

•Designed bumper parts and assemblies for the 787 Rolls Royce and General Electric thrust reversers using Catia V5 and Team Center were designed and defined as Model Based Definitions using Geometric Tolerancing & Dimensioning per ANSI Y14.5M. •This effort also involved pre-order parts and material before the completion of the engineering bill of materials by estimation for long lead order items based on non-released preliminary engineering.

Reverse engineered detail and assembly design engineering on Catia V5 and SmarTeam for a portable fuel systems tester so that another portable fuel system tester could be produced at a later date.

•Design engineered the structural components of the wing to body fairing on the 787 using Catia V5 mechanical and surface workbenches for highly contoured parts.•Project engineer for interfaces between the fuselage wing-to-body fairing an interfaces between the wing and wing-to-body fairing. Created Catia V5 Interface Control Model datasets to control fastener locations common to different product groups such as the wing and fairing, fuselage and fairing. Conducted meetings for evaluations of aerodynamic interface seals for the fairing.

Contracted to Gulfstream Aerospace to design engineer interior systems on the G550 aircraft in STC design in the mechanical final phase engineering department. Designed with Catia V4 interior commodities such as vanities, galleys, divans, and ceiling assemblies.

Investigated damage on Boeing 747 aircraft beyond the scope of Boeing's Structural Repair Manual and developed repairs based on research into the repair which in many case were similar to previously approved repairs. Proposed such repairs to Boeing Designated Engineering Representatives and customer representative for approval and agreement of such repairs. Both before, and during such repairs clarified the damage description and clarified the repair as needed with approved shop mechanics to aid and improve repair results.

Provided passenger to freighter kit retrofit structural designs specifically on floor beam reinforcements so that they could withstand higher loading conditions. This was for a wide body jet aircraft. Also design engineered fuselage retrofit fitting attachments for an all new retrofit cabin environmental ducting for the freighter design.

Engineered crew rest mount fittings that attached to the crew rest monument that in turn allowed it to be installed into general purpose structural rails mounted over the length of the main cabin in the upper crown area of a wide body aircraft. Integrated these fittings to insure fits with engineering groups responsible for the mount rails and minimal adverse noise transmission with the noise engineering group.

Contracted to Gulfstream Aerospace to design engineer interior systems on the G550 aircraft in STC design in the mechanical final phase engineering department. Designed with Catia V4 interior commodities such as vanities, galleys, divans, and ceiling assemblies.

Taught mechanical AutoCad, physics and mechanical design to undergraduate students.

Improved the design of MD-11 wing access panels from 100% laminate with stiffening ridges to a laminate honeycomb design. Design engineered support structure and wing to body fairings for a new DeHavilland DAS 8-400 aircraft, the panels of a complex contour laminate honeycomb design.

Made drawing changes for the King Air Series of aircraft retrofit kits.

Attended seminary in Washington state. Day-traded with savings to expand savings.

Provided structural mechanical engineering repair dispositions on the B-2, a large military bomber aircraft. Production experience was on the final assembly of the aircraft joining major sections of the aircraft together. Most repairs were of a structural nature, mismatched holes, double holes, scratches and gouges, structural gaps, structural clashes, assembly process failures, oil canning,

MRB engineering dispositions on mostly aluminum aircraft structures. Major fuselage body builds on the 747-400 resulted in mostly structural repairs for panel scratched and gouges, clashes in assembly, mismatched holes, double holes, holes in wrong locations, assembly process errors, needing engineering repair dispositions..

Designed the aluminum detail parts for a new wall mounted cabin attendant seat for the McDonnell Douglas MD-11 aircraft.

Interior retrofit engineering designs of a production Boeing 767 to a VIP interior. Added a bathroom vanity and modified ceiling panels to accommodate interior wall changes..

Provided structural mechanical engineering disposition on MD-80 and KC-10 aircraft during the fuselage build-up and final assembly. For both aircraft during the build-up focused on structural repairs while during the final assembly focused on control rigging repairs.