Patrick Brew Email & Phone Number

Washington, DC, US

Crossville, TN, US

Crossville, TN, US

Falls Church, VA, US

• Completed full spacecraft PDR quasi-static and buckling analysis in composite and metallic primary structural components for SpaceX Falcon 9 inertial launch loads using Siemens FEMAP
• Conducted quasi-static, thermal, and bolted joint analysis as a part of a C-Band reflector support structure trade study to optimize the weight of the design
• Derived loads from sine analyses to determine the appropriate load envelope for secondary structures
• Verified sine testing results for correlation to analysis during full spacecraft testing

Arlington, VA, US

• Authored the Aurora Flight Sciences Reverse Integration and Lessons Learned White Papero Summarized my experiences being the first Boeing-badged engineer fully embedded at Aurorao Included five recommendations on how.
• Served as the Enterprise Lead for the 2019 BCA Innovation Grand Challenge o Efforts resulted in almost six hundred fifty submissions – more than a 150% increase over the previous largest Boeing Innovation Venues.
• Organized tours and transportation for the 2018 and 2019 EAHI in-person matching eventso Coordinated transportation and tours of three Boeing facilities for over two hundred current and prospective teammates each year

Arlington, VA, US

• Analyzed over seven hundred NAVAIR replacement part requests by material, program, and certification requirements to determine Boeing’s positioning to deliver on additive manufactured spare parts
• Designed and additive manufactured an average of five emergent tools per month as requested by US military customers to improve safety and productivity for their operators
• Coordinated the shop replication initiative which will connect emergent shop floor tooling teams to existing solutions from across the enterprise
• Managed consortia projects with the Hughes Research Lab with regards to structural health monitoring on commercial products

Arlington, VA, US

• Collaborated with Aurora and BCA teammates to develop the first ground handling conceptual operations for a fully unpiloted vehicle and designed the panel lay out to best fit operator needs
• Trade studied and selected primary structural frames, longerons, and skin pad ups for the area around the skin cut outs of the aft cargo access door and two additional operator panels
• Configured over forty unique sandwich composite skin cut outs and penetrations using ramp downs and potting
• Designed pressurized refueling interface and routed the double wall fuel line through a congested region of the vehicle to create a lighter interface better positioned for ease of operator access
• Updated the Aurora Safety walk program which closed over thirty safety related action items during my rotation

Arlington, VA, US

• Used CATIA relational modeling to design the engine mounts, spar chords, and webs of the engine pylon for the Wing Integrated Propulsor
• Wrote a custom python parametric structural optimization code to trade study over five thousand configurations for the Wing Integrated Propulsor to determine proper structural sizing, pylon design, and material selection
• Completed the preliminary thermal analysis for the Cool Chain refrigerated ULD-3 project that shaped the business case and design of the container
• Participated in Advanced Concept idea generation and Product Development review sessions to start-up the first BCA Advanced Concepts program based in South Carolina

Arlington, VA, US

• Generated methods to automate the precedence network generation and updating for all one thousand wiring work packages in the 787 mid body
• Prototyped algorithms for automated precedence networking for almost two thousand mid body systems work packages for incorporation into a second century production IT tool
• Supported production directly through closing seven Kaizen cards through working on the Cell 30/40 Value Stream Team including two cards closed by working directly with the third shift production teams
• Interfaced between Design Engineering and Production through two ELRs which reduced the ergonomic impacts of an eight hour operation and eliminated non-conformances on the work package
• Generated two tooling actions which resulted in that improved flow of wheel well component installation

Arlington, VA, US

• Conducted fracture analysis on critical Hydraulic Quick Disconnects for Thrust Vector Control Actuators in the engine section of the Space Launch System using Finite Element Models and NASGRO
• Created methods to analyze structural integrity and fatigue in braided hydraulic flex hoses analytically and using composite modeling software, which contributed to the resolution of two RIDs
• Performed stress analysis analytically and using Finite Element Analysis on the ground support doors used during vehicle transportation and green run leading to major redesign of components
• Researched Power Spectrum Density Analysis and applied it to fatigue analysis of brackets in the Systems Tunnel
• Briefed program Core Stage Chief Engineer on two different critical path projects during special topics meetings

Arlington, VA, US

• Performed Durability and Damage Tolerance analyses for fatigue using numerical analysis and software packages
• Conducted a crack initialization and growth study for customer reported cracking in a structurally significant item to determine fatigue life of the component and ensure safe aircraft operation
• Evaluated stress corrosion cracking on structurally significant items for a new program by generating a nonlinear contact based Finite Element Model
• Generated response to customer questions regarding acceptable intervals in a flight critical region of the aircraft
• Designed and executed a fastener study to correlate FEM contact solutions to analytically calculated solutions and distributed results across numerous sites and programs
• Analyzed rain flow flight test data to determine fatigue cycles on landing gear components

Haslet, Texas, US

• Designed thermal management systems for electronic systems enclosures for government contracts
• Generated attribute driven models and GD&T drawings for parts I designed including sheet metal
• Created vendor item control drawings after fielding quotes and generating requirements
• Collaborated with Manufacturing & Assembly Division to implement a cost effective solution that is simple to fabricate and assemble.
• Wrote Engineering Change Notices for an existing chassis to save weight by shortening wire routes

Master’S Degree, Mechanical Engineering

Bachelor’S Degree, Mechanical Engineering