Sam Burdon Email and Phone Number

Focusing on multiple Hybrid Electric Drive vehicles, optimising reliability, functionality and performance. Remained accountable to the Company for the performance and delivery of their Traction Motor Test department. Leading a team of Mechanical, Electrical and Software engineers focused on development of diesel/hybrid drive systems. Managed the design, manufacture and testing of power electronics, battery systems, traction motors and vehicle cooling systems. Developing relationships with key customers to minimise project risk and to ensure expectations were aligned. Providing the Company with program reporting to align financial forecasting and project expenditure recuperation.

Senior Engineer Managing & leading a team of Engineers to test, commission and develop EV drive systems. Streamlined the Factory Acceptance Testing procedure by 60% for all production motors, ranging from 40kW, 100Nm to 200kW, 7500Nm motor gearbox units.Design, build and test high power electric motor and gearbox systems. Present test data for motor performance, system operation and software development.Lead the company to achieve UNECE Reg85 conformance.Design and make structural systems for the Test Rigs. Provide root cause analysis for motor/gearbox failures in the fleet.

Working as a contracted Design Engineer on engine externals of Rolls-Royces’ latest ‘UltraFan’ gas turbine engine to create multiple conceptual designs for fuel, oil, air pipework and supporting brackets, gearbox and control units using NX10 CAD package. Present the feasibility of the concepts within the engines architecture and assess against predicted performance characteristics. Collaborate extensively with Rolls-Royce’s engineering and program specialists and present my designs at formal ‘gated’ design reviews chaired by the Chief Engineer and his staff.

Project management focused primarily on Slip Rings and instrumentation design.

Delivering design/make engine instrumentation systems to support a Rolls Royce Flight Test program for the BR700 NextGen engines. Acting as Program Manager, I ensured seamless transfer of design requirements and technical data between the customer in Germany (Rolls-Royce Deutschland) and Aerodyn Ltd design team in the UK. Delivered complex mechanical structure installations for data acquisition units. Managed design solutions containing multiple thermocouple and accelerometer installations. Worked closely with manufacturing teams to provide technical documentation/hardware lead times and cost data to the customer. I also worked on the development, manufacture, assembly and installation (to ISO9001 standard) of a large, highly accurate/precise Coordinate Measuring Machine (CMM) used to inspect nuclear reactor cores of marine powerplant. Working closely with Software engineers and the engineering manager, produced the CE certification report, Factory Acceptance Test procedure (IEC 61511) and the operating and maintenance manual for the machine.

Delivering pipe/harness routing and retention bracket design to committed project timescales.Working across projects to ensure that my design solutions were compatible with other solutions being worked concurrently. Regularly promoted/defended my designs at gated reviews with company seniors. Working in close collaboration with the assembly line to support engine build on first article.Recognized as the focal point for Installations and Controls to process any assembly build issues and provided containment action to allow the build line to continue. Externals Department’s focal point for the Trent XWBs Flight Test Instrumentation packages.Technical support for suppliers at ITP aero in Madrid and TCS (Tata Consultancy Services) in Bangalore.

Apprentiship completed to NVQ level 3 - Engineering Technical Support.