- Lead metallurgist for metal AM laser powder bed fusion; working with Ni-Fe-Cr superalloys- Subject matter expert for specification-controlled mechanical standard parts including aerospace-grade fasteners- Performs failure analysis and consults on metallic materials and processes for new and recurring engineering across the entire launch vehicle including tanks, propulsion fittings, tubing, valves, feedlines, turbine pumps, and structures- Drafts, maintains, and improves material and process specifications- Conducts material testing studies to promote standardization, certification, non-conformance reduction, and productivity- Evaluates emerging metal additive methods for technology and manufacturing readiness levels and provides input on AM technology roadmaps and strategy to leaders, directors, and chief engineers- Provides evaluation and disposition of non-conformances to production and launch site teams- Identifies and reviews materials, parts, and processes to support obsolescence, product development, and reducing cost and lead time

- Planned and executed research projects on laser powder bed fusion (LPBF) processes, wire-fed electron beam additive manufacturing (EBAM), and post-build heat treatments- Technical and administrative lead for a metal materials laboratory; trained technicians, managed shared resources, performed sample preparation and analysis, and defined standard methods and work flows- Facilitated manufacturing processes for metal AM, brazing, heat treatment, machining, cleaning, inspection, and testing- Provided production support for raw materials including brazing alloys, fluxes, powder, and refractory alloys- Coordinated with suppliers on material processing, purchases, specification requirements, and inspection and acceptance- Managed procurement and install of capital equipment for growing and advancing laboratory testing capabilities- Designed test plans for assorted metal alloys; delivered analysis and reports on mechanical properties, thermal properties, chemical composition, microstructure, and phase composition- Drafted standard work instructions, product definition, and quality requirements- Researched key process-structure-property-performance relationships in LPBF titanium, aluminum, and ferrous alloys

- Organized and co-lead evaluations of major AM machine manufacturers for capital projects over $2M- Modified part geometries to optimize for the LPBF process, post-processing, and to ensure system compatibility- Managed prototype realization; performed product testing and collected manufacturing data for part qualification

- Reviewed and modified a landfill compactor design to ensure conformance with EU directives and ISO/EN standards- Produced drawings, test plans, and quality documentation for a CE technical file to enable sale in the European Union

- Worked as a team member on time-sensitive failure analysis investigations, manufacturing support, and research - Managed projects focusing on product qualification, post weld heat-treatment development, and indirect temperature measurements of molten steel through the instrumentation of furnace refractory brick linings- Performed metallographic sample preparation, simple CNC mill and lathe programming, tensile testing, impact testing, hardness testing, optical microscopy, and SEM imaging