Lead the design and development of residential and commercial battery energy storage systems (BESS). Work with fabrication shops, electrical and control consultants to build prototype units. Perform sheet metal design, design for assembly, and stress analysis of enclosure designs. Develop new battery termination strategies and help improve on battery design.

Responsible for new product creation from product design, tooling and mold design, product testing, process development to manufacturing. Areas of focus are new engineered structural composite (ESC) products, fluoropolymer hoses, ductile cast iron valves and plastic lined steel piping for corrosive fluid handling. Design and analysis using Autodesk Inventor. Documented testing and process work instructions.Designed and engineered a new ESC lined piping system to compete with dual laminate and lined steel piping systems. Utilized composite manufacturing techniques including resin transfer molding, compression molding, hand layup, filament winding, vacuum infusion and pultrusion/pulwinding. Trained end users and sales distribution offices on in-field product fabrication techniques.

Managed multiple projects from concept to production. Created custom engineered extrusion and molded prototypes to meet the needs of the customer’s application. Performed patent searches, DFMEA, DVP&R, tolerance studies, project timelines and budget tracking. Completed product designs using 3d modeling in Catia and Unigraphics. Contracted outside services for the design and manufacture of components, gages and tooling. Assisted in process development and manufacture of samples. Performed product validation testing and contracted outside testing services as needed. Provided technical support and installation of prototypes to OEM development vehicles. Produced Power Point presentations, aided in giving presentations and provided technical support for the sales and marketing group. Additional responsibilities included Packaging Engineering and design leadership.