Primary ME responsible for the design of a series of five electromechanical hubcaps for Boeing 737MAX aircraft. Complex, cantilevered plastic design had to withstand high vibrational loads and corrosive environment. Development testing with machined PEEK plastic. Primary ME responsible for the design of an electromechanical wheel to axle interface for Airbus. Responsible for bringing design from concept to production. Bearing Design, Plastic design.Mechanical Design Lead on 3 primarily mechanical Assemblies. Responsible for 3D CAD design, documentation, and BOMs during development process. Worked with a cross functional team to meet customer standards and industry regulations.Injection molded plastic subject matter expert. Familiar with highly engineered plastics, Nylon 6/6, ABS and other plastics.Designed several assembly fixtures.FEA and follow up Vibration Testing of Electromechanical parts.Designed R&D data collection box using Skeleton modelling technique. Design incorporated 5 boards, external connector, metallized PEEK plastic for EMI shielding, heat management, and external connector.

Concept design and prototype of Accessory storage bags/compartments to be attached to Defibrillation DeviceEarly phase design of main internal plastic chassis of M-PAK sub-system that acts as tie for multiple PCB boards and pneumatic pump.Research, identify, and test micro-porous membranes to meet requirements for air flow and IP55.

Design and build rapid prototype test fixtures to support validation testing.Clean up imported 3D surfaces and create offset surfaces to cradle devices under test

Part Design for major project and support of existing productsLed the mechanical design of a specialized electrical connector for AC to DC Power Supply. Resolved 50% failure of electrical connector and reduced part count by incorporating support foot into cord overmold.Optimized the design of very complex die-cast part for 5-axis machining as backup plan if there were issues with cast parts. Saved 8 hours of machine time over machining the as-cast shape.Revised the wire routing design for a laptop style display. Previous design had a blind closure that had a 3% pinched wire issue. Worked with manufacturing and purchasing to prototype solutions and modify production tooling.Participated in design review of mechanical stand components and gave input on hinge lock out mechanism, safety latch for removable splitter, and limiting features on floating connectors.

Product design & development, project management and collaboration with Taiwan manufacturing partners. Also responsible for product support and administering documentation system.Designed and led the development of the Revolution Bike Trainer. The product opened a new market for the company and won a Men’s Fitness Gear of the Year Award. Patent US 8,147,388Contributed several innovative design elements for the RevMaster Pro as a team member. The resulting look and innovations increased market share to be co-leader in the industry.Designed and brought to production the ergonomically correct and highly accurate g-Force Upright electronic bike. Patent US 9,440,106Created test plans and managed the testing of several products to comply with international standards, safety and product reliability goals.Provide continuous support for multiple existing products by performing root cause analysis and implementing reverse compatible solutions with Engineering Change Orders.Implement and manage the Enterprise PDM system including defining document workflow and providing training and support for US and Taiwan users.

Reduce and eliminate field failures and manufacturing issues.Designed a heart rate sensor that incorporated the industrial design preferred shape, eliminated false heart rates and prevented corrosion due to sweat penetration. Identified a urethane wheel where the urethane was molded directly to the outer race of the bearing to reduce field failures while maintaining high standards of durability and feel.Identified an alternate plastic material for an overmolded hand sensor that did not require additional tooling, eliminating a 40% failure rate in the field.Researched a die-cast ramp using Metal Matrix Composite material that consolidated three parts to reduce cost and field wear. Performed structural analysis of the design using finite element analysis.Product support of multiple products including resolving field failures, minor design changes, and implementation of production requested improvements.

Manufacturer of air and fuel system components for the heavy trucking industry.Design Engineer (ME II) 1998 - 2001Responsible for the project management of cross-departmental teams in an ISO 9001 environment. Designed die cast aluminum, injection molded plastic, sheet metal and screw machined parts using 3D CAD software.Managed a cross-departmental team to design, test, and implement into production a pneumatic air valve, which resulted in $180,000 in sales and was the basis for future valves, which generated an additional $250,000 in sales.Managed a project to design and implement a die-cast fuel cap that could be customized with customer logos and could accommodate any combination of thermal relief, pressure relief, and locking features. Product Support Engineer 1996 - 1998Modified existing products to meet customer needs. Generated drawings, specifications and assembly methods and coordinated the implementation with manufacturing.Developed an industry unique solution for casting a thermal melt-out ring for room temperature installation that eliminated burn hazard and hazardous lead/bismuth vapors from the facility. Technician 1996 - 1996Contract work designing line tooling, identifying product improvement opportunities, and performing qualification testing.