Stephen Mcdonnell Email & Phone Number

Philadelphia, Pa, Us

Albany, Ny, Us

Latham, New York, United States

• Manufacturing Engineer managing Plug’s highest volume fuel cell line, producing 60 fuel cell systems a day.• Wrote hundreds of pages of procedures for building and testing prototype and production units.• Designed and manufactured tooling for new processes and to improve yield of existing processes.• Machined dozens of parts on CNC and manual mill and lathe, often with quick turnarounds to prevent line stops.• Hand wrote NC programs to transfer manually machined parts to CNC mill, saving hours of cycle time per part.• Worked with internal departments and external agencies to certify three systems for compliance with UL 2267.• Coordinated teams of Operations, Quality, and Engineering to drive root cause analysis for failures found on theproduction line and in FAT.• Provided engineering support for small production runs of new products and small batch legacy orders.• Troubleshot fuel cell systems at various stages of testing and developed new inline tests to improve FPY at FAT.• Reviewed, corrected, and approved part and assembly drawings before production release.

Pontiac, Michigan, United States

• Programmed and proved out 5-axis machining operations for dozens of parts in materials including additively manufactured Inconel, Cast Inconel, Stainless 316, and Aluminum 6061.• Designed and manufactured fixtures for dozens of parts to repeatably hit size tolerances of ±0.0003” and 0.001” true position.• Wrote machine probing routines utilizing multiple coordinate offsets for parts with complicated datum structures.• Optimized NC programs for medium volume production runs of several hundred parts.• Designed custom tooling for gaging of tight tolerance features.• Worked with design engineers to adjust part tolerances and datums to improve part yield while maintaining part functionality.• Created work instructions and setup sheets for dozens of parts.

Ithaca, New York, United States

• Spent over 1800 hours in the machine shop manufacturing parts on manual and CNC mill and lathe• Co-lead a team of 40 undergraduate students in 2021 to assemble a launch vehicle for the Spaceport America Cup

Ithaca, New York Area

• Lead a sub-team of nine to design and manufacture a 14’ tall launch vehicle

Ithaca, New York Area

• Collaborated with a sub-team of 5 peers in 2019 to design, fabricate and test a solid potassium nitrate motor

Ithaca, New York Area

• Finished the design and improved upon a large centrifuge that is capable of testing components at 8gs of acceleration for an extended period of time• Improved the design and construction of the Shock Test Rig, which slams components into the ground to simulate the landing of the LV

Ithaca, New York Area

• Work with eight other staff members to develop a residential community for 270 first-year students• Develop interpersonal skills and mediate conflicts within the community• Create monthly floor and building wide programs, tracking resident attendance to improve program design• Collaborate with other departments at Cornell to host programs

East Aurora, New York, United States

• Developed scripts for single and multi-axis testing for Hellfire EMCAS motor qualification testing• Created tooling to assist in startup of G/ATOR production run• Refreshed work instructions to assist on startup of MK-48 steering assembly production run

Vergennes, Vt

• Wrote and revised hundreds of pages of documentation for Test Equipment• Reverse engineered a motor tester procured from another site with no documentation and created a drawingpackage and test procedure for it• Participated in multiple peer design reviews for various test procedures and products

Greater New York City Area

• Worked independently and under the guidance of a senior engineer to design handle press to save $.04 in laborcosts per brush• Repaired a wide variety of machines through every step of the production process alongside a senior mechanic• Independently fabricated dozens of wooden trays, lowering manufacturing costs from $200 to $100 each

Greenwich, Ct

I taught students anywhere from 4-40 years old basic and advanced techniques in Taekwondo.I trained alongside other instructors to help improve their skills and develop their teaching styles.I competed in national competitions and trained with other schools across the Northeast.