Sam Range Email & Phone Number

Falls Church, Va, Us

Mojave, California, Us

- Responsible for all aspects of aeroelastic design, analysis, and testing for the T-X vehicle- Designed vehicle suspension system and conducted ground vibration testing (GVT) to measure vehicle dynamic characteristics- Designed, performed stress analysis for, produced prints for, documented, and oversaw assembly of structural interface of aerodynamic flutter excitation system, defined interface with vehicle electrical and instrumentation systems- Managed aeroelastic NASTRAN finite element model and performed NASTRAN analyses to predict flutter and divergence behavior of vehicle- Defined flight test article instrumentation and data requirements, oversaw qualification tests of vehicle data acquisition and telemetry- Defined flight test envelope expansion matrix in cooperation with flight test crew, define all aeroelastic flight test points- Defined stiffness criteria for the design of speedbrake surfaces- Wrote automated signal processing routines to analyze telemetered data, compare real-world behavior with FEM predictions, enable in-flight progressive flutter envelope clearances- Developed and tested control room structure/flutter flight test engineer IADS screens, data processing tools- Ran structure/flutter control room station for first flight, all functional check flights, all flutter envelope expansion flights -- responsible for flight test data quality/collection, safety and clearance calls- Perform data analysis, summarize findings, and present aeroelastic predictions and measurements for pre- and post-flight briefings and flight readiness reviews to flight test team and management

Mojave, California, Us

- Responsible for the design, analysis, fabrication, and assembly of vehicle trailing-edge control surfaces (ailerons, flaps, rudder)- Built NASTRAN models of all surfaces, downselected load cases, calculated structural margins, presented stress reports for internal structure reviews- Designed and generated production prints for metallic hinges, actuator fitings, composite-metallic interfaces, hardware, composite internal and external components, composite assembly, and vehicle integration- Supported manufacturing crew with discrepancy disposition and repairs, manufacturability changes, tooling selection, and in-process measurement and verification- Designed loading and instrumentation jigs, defined test plans, conducted testing, and processed data to determine surfaces meet static strength and stiffness requirements

Mojave, California, Us

- Defined the first vehicle manufacturing plan in conceptual phase -- determined major tooling and assembly breaks, sub-assembly manufacturing and integration sequences, manufacturing and maintenance access requirements, and produced manufacturing diagrams and storyboards for zone designer and manufacturing staff guidance and planning- Performed conceptual stage calculations for initial wing skin/internal structural sizing, selected vehicle composite structure fibers and adhesives, determined order quantities for all composite materials- Designed and defined all outer mold line hard tooling -- wings, fuselage, stabilizers, etc. -- including all flanges, scribes, metrology and other production features- Organized construction of a custom oven for curing of large composite parts- Principal designer for main wing structure -- designed all tooling and jigs, defined door locations and sizes, produced all part and assembly shop definition (over 500 drawings), defined repairs, and directed major machining and bonding operations on shop floor- Directed material and process qualification for several new composite material and joint types, documented test results- Coordinated with vehicle system designers and stress analyst to provide suitable access and penetrations for fuel, hydraulic, electrical, instrumentation, and flight control systems- Designed wing-to-fuselage attachment and performed stress analysis for fittings, directed wing assembly, machining operations, and fitting assembly on the shop floor

Mojave, California, Us

- Produced part fabrication drawings and supported manufacturing crew fabricating prepreg composite components- Reported and dispositioned part discrepancies and defined repairs- Developed new trapped-rubber technique for fabricating hollow tube parts- Led 8-person manufacturing crew performing a complex large-scale multi-month-long wet layup process, oversaw postcure and nondestructive testing, and defined repairs for finished parts- Coordinated response to large material contamination event -- determination of material origin, laboratory testing of contaminant type and amount, material testing of contaminated structural articles, repair and cleaning of flight articles, and documentation of findings

Mojave, Ca, Us

- Designed collapsible, stowable towbar for White Knight Two -- conceptual design, sizing, joint design, stress analysis, engineering drawings, and work instructions.- Developed test plan, designed test fixture, and carried out testing to characterize performance of impact-damaged prepreg laminates.

- Lead structural and manufacturing process design in team developing proof-of-concept micro-UAS (Perdix) deployable in-flight from countermeasure flare launcher.- Design and fabricate unique tools and integration workflows for high-precision gage-limited composite components.- Plan and instrument wind tunnel, structural bench, and flight tests for performance validation.

Supported the development of diverse consumer products with mechanical, electromagnetic, and aerodynamic design, analysis, prototyping, and evaluation.- Designed, optimized, and tested small-scale wind turbine- Designed low-cost brushless alternator for turbine- Designed injection molded components and assemblies for wide varieties of consumer electronics.