electro-mechanical-pneumatic testing on new lead and catheter designs used in Therapy Delivery (Stimulation and Drug delivery to CNS sites)

Contractor working at Medtronic - electro-mechanical test new/legacy product designs for neuromodulation therapy delivery leads and catheters.

Engineering support of laser micro-welding process during manufacture of implantable medical devices. Process development/improvement and hands-on electro-mechanical support for 43 lasers in 5 manufacturing departments laser micro-welding and engraving metal and polymer components.• Composed FDA required technical reports, statistical analysis in MiniTab of destructive analysis welding penetration data, and submitted for Regulatory approval as per 21 CDR (QSR). • Tested laser… Show more Engineering support of laser micro-welding process during manufacture of implantable medical devices. Process development/improvement and hands-on electro-mechanical support for 43 lasers in 5 manufacturing departments laser micro-welding and engraving metal and polymer components.• Composed FDA required technical reports, statistical analysis in MiniTab of destructive analysis welding penetration data, and submitted for Regulatory approval as per 21 CDR (QSR). • Tested laser performance providing data analysis of laser (optics, power supplies, galvos, automated vision system) parameters: changing pulse width, pulse frequency, peak/avg power.• Modified tooling and product fixturing using Solid Works.• Green Belt Statistics Training, DMAIC, and Lean Manufacturing.• Provided 24hr on-call support for production laser welding processes, troubleshooting/resolving quality issues, determining acceptance/rejection, implementing corrective actions (CAPA)• Certified laser operators on laser welding processes, assuring critical quality criteria knowledge and class-4 lasers were safely operated.• Analyzing historical data for trends and process improvements. Identifying equipment/material variations that may be effecting process capability (CpK)• Performed and documented laser maintenance including optic/cavity alignments (optimizing TEM00) and beam analysis (Spiricon software) on class 4 lasers. Lasers: Nd: YAG lasers include Lumonics, Lasag, Trumpf, and Rofin-Baasel laser markers. IPG and JDS Uniphase fiber lasers. Flashlamp, diode, and fiber excitation methods Micro-welding and surface modification of various metal and plastic components. • Programmed laser engravers and HMI Cognex visual (x, y, z-axis) software for welding & surface modifications of titanium, aluminum, and stainless steel. components (batteries, capacitors, molded polymer casings) Show less

Maintained ISO 17025 accredited mechanical test lab. Using ASTM, GM, Ford, UL, Mil-Spec test methods, compared surface finish changes during neutral salt spray (corrosion), and other environmental & mechanical tests on treated metal and plastics substrates using wet chemistry analysis. Documented test results and test equipment calibrations and repairs.• Performed preventative maintenance & repair on mechanical, electrical, and pneumatic systems on 5 neutral spray test chambers… Show more Maintained ISO 17025 accredited mechanical test lab. Using ASTM, GM, Ford, UL, Mil-Spec test methods, compared surface finish changes during neutral salt spray (corrosion), and other environmental & mechanical tests on treated metal and plastics substrates using wet chemistry analysis. Documented test results and test equipment calibrations and repairs.• Performed preventative maintenance & repair on mechanical, electrical, and pneumatic systems on 5 neutral spray test chambers, and 3 test ovens.• Conducted an average of 55 concurrent multi-month tests providing daily updates to clients and DuBois product salesmen.• Lead the lab to pass ISO 17025 accreditation audit in 2004.• Reduced testing costs by 33% by adjusting specific gravity (change in concentration) with a $40 refractomer and using inexpensive caustic soda as the pH adjuster in each salt bath batch. Show less

Researched and designed optical test benches for prototype diffractive optics and DWM gratings used in fiber optic cable connections. Assisted in Design and Manufacturing Failure Analysis (DFMEA, FMEA) of new products. Supplier Quality Department representative to vendors and suppliers. R&D level troubleshooting support and advanced training to manufacturing metrology technicians on CMM, SEM, and laser measurement systems. Built prototype lens systems, troubleshooting with Zemax… Show more Researched and designed optical test benches for prototype diffractive optics and DWM gratings used in fiber optic cable connections. Assisted in Design and Manufacturing Failure Analysis (DFMEA, FMEA) of new products. Supplier Quality Department representative to vendors and suppliers. R&D level troubleshooting support and advanced training to manufacturing metrology technicians on CMM, SEM, and laser measurement systems. Built prototype lens systems, troubleshooting with Zemax software.•Built Delphi database for production measurements for Quality Control Analysis queries and investigations. Wrote CMM programs in Quindos (a Brown & Sharpe CMM program language). Programmed Zeiss and Mitutoyo CMMs for R&D projects. Show less

Provided optical and surface metrology support for molded prisms, cylindrical, diffractive, aspherical, and spherical lenses. Acrylic, styrene, polycarbonate, and special engineered plastics. Determined critical features from print, designed Zygo interferometer testing and fixturing for production use. Set SPC process limits for manufacturing. Trained quality technicians to perform tests.• Project Lead – OC Metrology Planning Project: Reduce First Article Inspection and delivery time… Show more Provided optical and surface metrology support for molded prisms, cylindrical, diffractive, aspherical, and spherical lenses. Acrylic, styrene, polycarbonate, and special engineered plastics. Determined critical features from print, designed Zygo interferometer testing and fixturing for production use. Set SPC process limits for manufacturing. Trained quality technicians to perform tests.• Project Lead – OC Metrology Planning Project: Reduce First Article Inspection and delivery time, and increase quality. Procured $200,000 CMM for department.• Project Lead – 12 lens light screen product—used DOE techniques to optimize throughput. Tripled output from 15 to 60 parts/hr. Replaced UV-cured glue with ultrasonic welding that resulted in increasing quality throughput from 30% to 99%.Also provided process engineering support for surface finishing, wet grinding, coring, and anti-reflective coating deposition on acrylic and glass optics. Show less

Manufacturing Technology (Corning)Entry level mechanical design of production fixtures and test rigs. Created drawings (AutoCAD, Mechanical Desktop) and bill of materials for fabrication and documentation. Light machining, drilling, tapping, grinding, basic G-code programming. Return Product Analysis (RMA) investigations.

Aviation Electrician's Mate 1st class. Electronic/Electrical Maintenance: intermediate & Bench level; test and repair radial and jet engines, fuel systems, inertial navigation, weapons, avionics systems on F4/F8/A6/E2/F14/F18. NAS Kadena (Okinawa, Japan) Flightline supervisor.Designed & Supervised Navy's 1st aircraft cable repair shop (SanDiego); Aircrew on a Douglas C-117D Skytrooper transport aircraft.