Director Structures, Karem Aircraft
Lake Forest, California, Us
I lead a design and manufacturing team of six engineers and technicians through the Joint Heavy Lift program and Karem TR53 tilt-rotor development. I was in charge of composite structural analysis, design and manufacturing concepts as well as selection of facilities, equipment, and general recruiting.• Directed design and manufacturing of Karem TR53 tilt-rotor; manufacturing large carbon airframe lamination tools using low-cost tooling approach with a team of four and a tooling budget of less than $1mil. Large laminate tools produced by a team of four in less than one month from initial CATIA surface layout through low cost master machining and OOA carbon tool face and carbon honeycomb backer assembly.• Oversaw the construction and installation of $5mil + manufacturing facility including large gantry router, low and high temp ovens, kitting machine, spray booth and custom workspaces.• Worked closely with government officials at AFRL, NASA and AATD to determine the operational needs of America’s future heavy lift vehicles. These interactions exemplified the benefits of a close interaction between policy, technology and end user execution. • Worked with large and small composite material vendors to develop custom solutions for our manned aircraft design. Worked with Army, Air Force and FAA personnel on the future requirements for 30 yr service life composite airframes.• Helped develop design of multi-celled, co-cured rotor blade and a patented manufacturing method to produce the structure.• Developed streamlined production quality prototyping techniques for bonded only A400 size fuselage concept on JHL program.• Conducted several briefings of DARPA, Congressional and Pentagon officials on the Army Joint Heavy Lift and TR-53 tilt-rotor programs.