Creating new products, testing present products, and assisting others while we are setting up our new facility.

Designed their latest hitch mounted bike rack (GiggaWatt), a heavy-duty rack aimed at the E-bike market. Leveraging a few positive features from their prior products, performing FEA on component and assembly level items to balance strength, weight, cost, and ease of assembly.4 months from napkin sketch to partially functional prototype.10 months to a fully functional and testable prototype.12 months released to manufacturing for production. Other tasks.Helped release 4 data packages and BOMs for a new product line that was almost complete when I arrived. Created a new project folder structure, reducing the disorganization by 75%. Created, tested, and demonstrated new part, assembly, and drawing templates, these reduced drawing creation by 25% and captured component specifications.Support of existing product lines for engineering, manufacturing, sales, and customer service. Redesign of a few existing sub-assemblies on existing products due to failures. Mentoring a colleague on best practices for cad modeling, drawing, creation, BOM creation, and manufacturability. Performing multiple small design reviews on existing product fixes that are in the works. Unloading truckloads of product, palletizing, and getting them into our warehouse monthly. Small company everyone pitches in when a truck shows up.

Designed, built, tested, documented, presented, and delivered to the USG a custom extrusion head that fits onto an off the shelf 3d printer (please see page 3, sample 1). Took this project from ideation to functioning prototype for customer testing in 1.5 years at an approximate 30% profit for CAPCO. Customer went from crickets to excited during this time frame.Designed, prototyped, tested, polled people, and iterated a few versions of ergonomic and more easily manufacturable forward and rear grips for an existing military weapon. The new grips were approximately 25% the cost of goods of the present grips, 10% the assembly time (forward grip), with huge improvements to both grips regarding ergonomics. Also created recoil mitigating butt stock concept for this same weapon. Reviewed ~ a hundred 3d, 2d, and combinations of cad files for quoting purposes from a few potential customers. Created complete discrepancies list of all files and provided this to managers for review. Creo (aka Pro-e):I taught 2 engineers how to set up and efficiently use Creo 4. They both made immediate & long-term improvements to their projects. Created, tested, and demonstrated new templates: parameters list/s, part template, assembly template, formats (editable and configurable for any drawing size), drawings templates (A&B size), and tables (2 sets of title blocks wide & a tall, 3 for bills of materials) for the engineering department. These were being used the day I completed them by most of the team. Simple file creation improved by 15% and more complex assembly and drawing creation improved by 50%.CAPCO had mass layoffs. The RD group was cut.

Designed multiple concepts of a film framed wafer carrier (sample 4) for a European consortium called TSV-Handy that is spear heading a new product line for wafer processing equipment. The final concept was 3d printed for assembly, validation, and presentation to the consortium. The intent of this work was to keep Entegris in the lead of the industry by shoring up existing relationships and gaining new ones. Much of semiconductor manufacturing follows SEMI standards. Typically, the first to market with a customer accepted product has the opportunity to lead the creation of the standards that all others would need to follow thus creating themselves a substantial advantage by having months if not years of lead on the competition. Engineering lead on new diffuser technology for 4 versions of FOUP products (samples 5 & 6). Utilizing 3d cad, flow simulation, 3d printed prototypes for evaluation testing in internal engineering lab, machined and molded parts for broader testing in internal & external test labs and in customer facilities. Manual machined my own weld dies to make hundreds of test samples upon customer request for the technology. Transitioned 1 of the 4 versions of the new diffuser technology into LVM. Patent granted for membrane diffuser substrates. [US-2020-0075374-A1].Spear headed and set up an EFEM in the engineering lab. Created basic work instructions on how to operate it allowing all from engineering to test their FOUP related projects on a real piece of customer equipment at a basic level gaining valuable empirical test data to correlate to simulations.

Protocol Insights: Design of enclosure for their analyzer product (sample 8). They were a startup, and this was their first product. Keeping the prototype and first 10 for sale units as cost effective and flexible as possible was a priority. Fast Plastic Parts: Review customer injection mold part & assembly designs for manufacturability, fit, form, and function. Redesign the majority of customer cad files to be injection moldable and still maintain or improve the functionality of their initial designs. Design simple Aluminum injection molds. Work with CNC programmers and machinists to ensure we have all tooling and material to produce molds. Initial part inspection upon first shots off the injection molding machines. Jabil (May 2014 - August 2015, full time): Contract mechanical engineering and design, specifically for industrial cooling products and data storage devices. Updated their SolidWorks templates initially.Prescott's Manufacturing: Manufacturing facility, mostly machining and injection molding. I designed 3 products for one of their customers called Playtime LLC. Wall hanging toys for restaurants (sample 7), plastic enclosures housing electronics. XIO (Jan 2008 - Jan 2012 full time): Data storage company. I was working on the next generation of their server called the ISE (samples 10 & 11). Creating 3d cad for complex PCBAs, air flow, and vibration were challenging aspects of this product. Initially I re-created the whole server assembly. Once all cad matched the actual parts then I was able to serve the team by designing new iteration and revisions of previously tooled items to accommodate the team’s new electronics designs.

Designed, prototyped, tested, and assisted manufacturing in the production of industrial floor cleaning equipment. My primary product was the rental unit called the Mini-Pro (sample 3), the smallest of their product offerings aimed at rental and small office buildings. Cost down of an existing vacuum shoe that was used on an older equipment line, one of their flagship products. This new design reduced the steps needed to remove and install by 75% about a 45 minute reduction. This was important as this assembly was removed and cleaned as often as every shift depending on the environment used in. Windsor Industries goal when I was hired was to launch a new product line (the Mini was 1 of 4 in the new line). The bigger picture goal was to attract a larger company to purchase them as the family wanted to sell and retire. All of these goals were met in about 16 months, 2 months ahead of the plan.

Traveled all over the USA for the first 6 months performing upgrades to all sorts of the prior model year equipment, primary focus on treadmill and incline trainer products. This was valuable to the company and myself getting to learn the products very quickly. Designed, prototyped, tested, and assisted in the fabrication of club level fitness equipment. Primarily managed the treadmill and incline trainer product lines (sample 2) from napkin sketches to the club floor and any iterative, customer, or sustaining activity in between. Worked with management, sales, marketing, manufacturing, industrial design, software, electrical, testing, and outside vendors for prototypes, low volume, and full production. Figured out how to create 1:1 for copes of our tubing members of all shapes. This saved hours every day in fabrication time for our prototypes and low volume frames. It also gained an all-access pass to the fabrication shop, the fabricators loved the new things we could provide them. Designed the molded components for all the equipment lines (strength, stationary bikes, and other cardio equipment’s).There was a transition of cad packages from Pro-e to SolidWorks within this division and almost no experience designing plastic components. Within the first year I was able to be a training resource for those team members needing SolidWorks help and was the local expert when a plastic molded component was needed for any product. Saving the company thousands of dollars in external training expenses, having immediate tangible training on the products they were working on, allowed me to gain a greater knowledge of SolidWorks, plastics, and the other product lines. Attended trade shows to set-up, tear-down, and be present at the booths we had as a promoter and demonstrator of products.

Designed roto-molded components for semiconductor manufacturing equipment and trim fixtures for those parts.Worked with production staff to refine molding, assembly, and other processing methods. Procure tools and material for new fixtures where needed.

During college I worked 16-35 hours per week for P.R.D., a very diverse company that has design, rapid prototyping, testing (field and bench), manufacturing, and assembly of drive terrain systems and components for companies like Polaris and Club Car. I did assembly and disassembly of drive terrain components like rear and front ends on 4x4 ATVs for the engineering team. Taking measurements and documenting findings. Laying out the components in a neat and clean manner for the lead engineers to review. If I got lucky occasionally was paid to ride and try to break in a systematic method instrumented ATVs and snowmobiles, this was awesome!After I proved myself, they gave me a small project. The Quick-Tach Tiller for John Deere Weed Trimmers. I managed this project from the drawing board, through testing, cost reduction, and onto Home Depot’s shelf (68,000+ units sold first year).