• Created mechanical designs of military modular electronics hardware meeting standard spec requirements. Concept designs with high quality renderings and animations generated new business for communication enclosures and military radio applications.• Designed conduction-cooled PCB enclosures, heatsinks, and brackets. Performed dimensional checks on all first articles and ran thermal and structural FEA simulations to optimize cooling within tight envelope. Specified conductive paste and validated cooling performance with thermal camera. Published mechanical drawings for fabrication, build guides, and Bills of Material for procurement. Facing a 30 week supplier delay, 3D printed a functional 48-pin connector that delivered on time as part of the product tool set.• With no company testing record, initiated and owned shock and vibration testing to meet MIL-STD-810H. Wrote Statements of Work, identified labs, and designed support fixtures. Collaborated on test plan, setup, and data collection. Gave company-wide technical presentation of results; successes and challenges, establishing baseline performance of company’s main product line.

• Managed full NPI development of multiple concurrent battery pack assemblies ranging from 1 to 400 cells, meeting diverse requirements for medical device, utility, land- and water-based drone, and R&D customers while working remotely and independently.• Supported all teams during the full product lifecycle from concept to production: sales, engineering, customer approval, purchasing, planning, test certification, manufacturing, quality, and shipping.• Prepared complete product documentation packages: Component, assembly and sales drawings, ERP BOM, test certification, product specification, and manufacturing procedures. Optimized ECO and drawing release process flows.• Designed manufacturing fixtures and tools to enable ESD-safe PCB BMS smart board assembly and cable routing.• Introduced advanced CAD tools including SolidWorks design tables, large assembly management, and parametric templates.• Used DFM/DFA/DFX on all new products and optimized legacy products while maintaining external customer requirements.

• Acted as NPI project manager, team lead, design engineer, drafter, and technician for overmold cable assembly and connector product lines for aerospace, military, civil, and industrial customers. Multi-tasked an average of 4 projects at any given time meeting customer specifications on time and within budget.• Managed projects to meet budget and timelines for all project designs, BOM, and manufacturing documents. Ran cross-functional team meetings and design reviews with mechanical, electrical and manufacturing engineers, purchasing and global manufacturing operations to track priorities and manage risks. Mentored junior engineers on concept-to-production phases.• Used advanced CAD techniques in SolidWorks including surfacing, design tables, structural FEA simulations, and DriveWorks configuration software to create complete manufacturing-ready documentation.• Made functioning 3D-printed rapid prototype injection mold cavities, expediting the development cycle of new product lines.• Coordinated, wrote test plan and prepared supporting hardware for EMC/EMI testing.• Implemented PDM Professional database software, created data cards, and developed process flow while acting as PDM administrator.

• Provided remote and on-site contract engineering services to multiple clients across several industries, executing projects on schedule with little to no supervision. Installed and debugged systems at customer sites preventing production line downtime.• Designed stand-alone PCB environmental chambers and testing equipment. Drafted complete manufacturing documentation packages and managed fabrication vendors. Optimized designs with SolidWorks structural, vibration, and thermal FEA. • Owned full sets of manufacturing documents. Created custom parts, assembly, and drawing templates to streamline creation.

• Directed project team to develop a paradigm-shift manufacturing system to integrate into the vendor’s furnace: Managed tasks for design and test engineers. Co-invented improvements resulting in one patent application and five invention disclosures to date. Ran DFMEA exercise, owned Risk Matrix, and built DVP&R. Designed mechanical components utilizing DFM (sheet metal, castings, tooled parts, and weldments) and reviewed team drawings for GD&T requirements. Design improvements reduced process cycle by 35%, lowered equipment capital costs by 75%, and met aggressive scaling targets.• Performed comprehensive mechanical design of fuel cell processing station: Generated solid model and manufacturing document package using SolidWorks. Conducted multiple structural and thermal FEA simulations. Specified off-the-shelf parts and managed subsystem development with an external piping vendor. Eliminated operator exposure to a skin irritant and reduced manual installation labor time by 85%. Built and debugged nine systems by hand. Two hundred of these robust and reliable systems are currently in use and were prominently featured on 60 Minutes segment on CBS. Received QCD Award for achievement.

• Led complete mechanical engineering design and development of power electronics enclosures for the US Navy Advanced Arresting Gear Program. Directed and oversaw a team of designers to model components using Pro/ENGINEER. Calculated stresses with MathCAD and created FEA reports using HYPERMESH and ANSYS to meet 80G shock and vibration requirements.• Executed ground-level development of US Army soldier fuel cell power system. Conducted journal, literature, and patent research. Performed material stress and chemical yield trade studies. • Fabricated prototype and conducted validation testing; development was 75% faster than the competitor.

• Created ultra-high purity semiconductor chemical containers and fluid delivery systems to generate new business for semiconductor OEMs. Designed and drafted using Pro/Engineer. Developed product recycling system for safely containing a highly-corrosive wet chemical.• Achieved DOT certification for container packaging. Generated comparative component test reports, system operating instructions, and cost analysis reports.• Intercepted unsafe chemical container assembly. Designed plastic injection-molded safety fixture eliminating injury risk, resolving prior losses totaling $2.3 million in accident damages.