Patrick Merrill Email & Phone Number

Ballston Spa, NY, US

Gardner, MA, US

• Carried out First Article and AQL inspections of parts for injection molded, cast urethane, CNC, and 3D printed components.
• Collaborated with customers on new and transfer tool and part launches to ensure parts meet customer IQ/OQ/PQ requirements
• Created validation, PPAP, SPPV plans to validate assembly and injection molding processes and parts for ISO 13485 medical devices
• Created work instructions for assembly processes and migrated existing instructions to TULIP
• Integrated traceability requirements and tracking of failure modes and MRB components into TULIP work instructions
• Generated inventory management documentation and shortage reports for customers and suppliers

Denver, Colorado, US

• Managed company inventory of raw materials, components, prototypes, and production parts across suppliers for prosthetics manufacturing.
• Implemented and maintained company quality management system, ensuring parts met design specifications and manufacturing requirements.
• Generated solid body models and detailed engineering drawings (ANSI Y14.5) for components using SolidWorks and Fusion360.
• Contributed to product design, execution of production and prototype products, and development of manufacturing procedures.
• Developed test methods for quality assurance and conformity to ISO standards and CE marking.
• Collaborated with suppliers and vendors to improve manufacturing processes and meet specifications, overseeing development runs for quality and efficiency.

Denver, Colorado, US

• Translated product and market requirements into specifications and executed iterative modifications based on testing results.
• Designed components, assemblies, and features, developing FEA models for simulation and evaluation.
• Worked with University researchers to characterize custom material and develop testing protocols.
• Carried out structural evaluation tests
• Created preliminary 3D scanning protocol for failure mode analysis (FMEA)

Denver, Colorado, US

• Designed finite element analysis model (FEA/FEM) for comparing the effects of different intramedullary nails
• Compared stress shielding/load sharing effects of intramedullary nails, ankle plating, and bone screws
• Compared compression values for nails when exposed to a resorption zone
• Segmented QCT scans in ScanIP and combined with medical device CAD models for use in Finite Element Models
• Recreated medical devices in SolidWorks, from samples provided by manufacturer
• Produced force-displacement and stress-strain curves for finite element models

• Designed prototype construction equipment using SolidWorks
• Reverse engineered existing products
• Sourced parts and prototypes from manufacturers in China
• Oversaw production of prototype construction equipment
• Assembled prototype construction equipment
• Refined designs based on field testing of equipment

St. Louis, Missouri, US

• Led a team of three members to perform underground and surface surveys of mining operations
• Maintained inventory for the surveying team
• Compiled survey notes to update mine maps
• Designed surface and underground mine plans in AutoCAD for active, inactive, and future mines
• Worked with federal and state regulators (MSHA, OMSL, KPDES, VDMME) to approve mine plan alterationsand additions as well as address on-site concerns
• Used underground surveys to create daily production reports and yearly budget and progress reports

Master Of Science - Ms, Mechanical Engineering

Bachelor Of Science - Bs, Mining And Mineral Engineering