Robert Gibbons Email & Phone Number

Phoenixville, PA, US

West Chester, Pennsylvania, United States

West Chester, Pennsylvania, United States

• Serving as subject matter expert in laser welding with responsibilities including developing laser welding parameters for new motors, troubleshooting manufacturability issues, and strengthening our knowledge base by.
• Collaborating with operators and engineers to design, manufacture, and validate new tooling for new products
• Continuously improving manufacturing processes and contributed design recommendations to make new products more manufacturable
• Preparing PPAP packages with contents including Control Plans, Process Flow Diagrams, PFMEAs, Material Certifications, FAIRs, Process Validations
• Planning and coordinating preproduction builds to meet customer deadlines while providing appropriate updates to internal and external teams

Dearborn, Michigan

• Supported the launch of new vehicle programs at Ford’s Kentucky Truck and Ohio Assembly Plants
• Designed and released chassis components including frames, heat shields and skid plates
• Developed DVP&Rs, 8Ds, and other documentation to capture design validation, errors in production, and durability robustness actions
• Engaged teams within Ford and liaise with external suppliers to develop solutions to cross-functional issues
• Responded to issues in current production and pre-production builds by developing interim containment actions and permanent corrective actions
• Optimized existing designs to realize annual cost savings of ~$2.2M on various vehicle programs

Philadelphia, PA

• Worked with a Senior Design team to design a semi-monocoque structure capable of transporting one person at a rate of 200 mph, on a mile-long test track
• Constructed a scale model of the competition design out of carbon fiber
• Designed the structure and created the full Hyperloop pod assembly in SolidWorks
• Preformed various ANASYS analyses to research nosecone buckling, floor strength, and load paths

Philadelphia, PA

• Participated in Formula SAE, a yearly competition held between colleges or universities to create a race car which is designed, machined, and fabricated by the students
• Fabricated control arms, brackets, bearing cups, and firewalls
• Created parts out of carbon fiber using wet layup and vacuum resin infusion manufacturing techniques
• Led a student group of 50+ active members while managing a yearly budget of $36,000
• Created ANSYS optimization analysis to optimize the chassis strength with various tube profiles

Aston, PA

• Assisted engineers with the design of the next generation of UAV launchers
• Helped assemble, test, and analyze data retrieved from the next generation bench test unit
• Supported the component selection for a heavily customized UAV launcher
• Collaborated with engineers and shop personnel to update and correct assembly drawings for a wide array of aircraft arresting systems

Exton, PA

• Programmed visual inspection tools to quickly and repeatedly inspect parts using metrology programs
• Designed and created drawings in Creo for fixtures to accurately orient and inspect a wide array of medical screws using Keyence and Starrett vision systems
• Assisted with multiple polymer extrusions under clean room conditions

Concordville, PA

• Designed and fabricated fixtures for testing and displaying position-controlling devices
• Assembled five different prototype designs and produced over 500 units of each to send to customers and potential clients
• Created and revised models and drawings using NX and Team Center
• Designed, fabricated, and assembled a display system for a computer monitor arm for our sales team that could be shipped to trade shows and easily assembled