• Leads/mentors two mechanical engineers/designers• Creates housings for RF measurement equipment

Engineering electrical and mechanical solutions for the Caddy and Lenton brands

Analyzed and corrected the component level and system level design of electric/pneumatic mechanical landing gear actuators• Reworked the 3D CAD models to show movement—identified multiple failures• Predicted potential problems—those same problems showed up during testing• Utilized FEA and hand calculations to solve seal and weldment issues• Developed design solutions—carefully documented a plan for the needed redesign

Stood up new engineering department for fabrication company making primarily large custom race hauler trailers• Led team of 4 engineers—oversaw hiring of 1 mechanical engineer and obtained approval for 1 electrician to move into the engineering group• Researched technology needs—obtained approval for SolidWorks licenses, including mechanical, analysis, electrical, and Product Data Management (PDM) packages• Developed design guidelines for weldments and bent sheet metal components• Obtained and demonstrated accelerometer and data acquisition (DAQ) systems• Researched and recommended welding standards, and predictive strength equations for both static and dynamic (fatigue) loading

Developed Ram Air Turbines (RAT) and Brushless Starter Generators (BSG). Designed, installed, and operated wind tunnel test fixtures. Created engineering design tools. Wrote assembly procedures, test plans, and specifications. Coordinated with suppliers, customers, purchasing, and test facilities.• Created robust turbine fixture—capable of 20,000 RPM with 1,000 lb thrust load• Ensured safety by utilizing Finite Element Analysis (FEA) stress and modal analyses• Assembled own test fixtures, ensuring testing completed ahead of schedule• Conserved company resources—originally $80,000, final cost under $10,000• Created bearing design tools from basic principles—text book said it couldn’t be done• Modeled RAT deployment kinematics with macro—optimized suppliers’ actuators• Created numerous design configurations for tradeoffs—selected optimum layouts• Used phase change material for thermal issue—mass reduced from 2.00 to 1.17 kg• Created several thermal models for dissipating heat generated by power electronics in BSG—tests validated predictions—transient within 3ºC, steady-state within 10ºC• Designed for additive manufacturing—features impossible with traditional methods• Recreated F-15 generator housing models and drawings using 3D scan technology

Performed user research, created prototypes, developed designs, coordinated efforts of 5 engineers, and released files for production tooling of floor care appliances.• Built own prototypes for stair cleaning—user research led to development project• Oversaw prototyping of vacuum cleaner for user research—concepts validated• Developed concepts and coordinated efforts to release files for production tooling• Created difficult 3D CAD models—involute bevel gears with non-perpendicular axes

Created concepts, machined and tested prototypes, and made drawings for saws. Coordinated with engineering team in performing Finite Element Analysis (FEA).• Invented automatic, narrow mobile stand—includes support for long rip cuts• Designed rail locking mechanism—ergonomic shape, one-handed adjustments• Created multiple concepts for removable wide rip capacity—fast, tool-less changes• Developed fence rail attachment, fence storage, fence face locking, blade release tools• Solved design problems for other team members—tilt adjustment, blade guard• Performed FEA for engineering team—optimized material, increased strength, achieved target forces, determined correct material selection• Created own prototypes—including machining with vertical end mill and metal lathe• Captured high-speed video—analyzed blade brake firings to ensure safety of product

Researched, prototyped, and publicly demonstrated new ideas for power tools.Prototyped next-generation finish sander—minimized time to acceptable finish• Theorized and modeled causes of sanding “tracks”—testing validated theory• Worked with NASA to develop equipment for quantitative surface measurement• Created sander that quickly switches between random orbit mode and orbital mode• Made fast-change sanding pads—quick grit changes, allows lower cost sandpaper• Developed retractable sanding pad brake—less time sanding and longer tool life• Demonstrated concept for altering sandpaper—reduced stray scratch marksCreated next-generation band saw prototypes—product manager said the following:“I would like to make sure that we lock up these designs ASAP. The initial feedback was so overwhelming that I don’t want us to miss this opportunity for patentable innovation.”• Made blade changing easy—reduced blade changes to 1/4 of the needed time• Invented blade guides that automatically adjust with minimal user interaction• Created split table—enables fast blade removal and access to lower guides• Invented blade clamps—holds blade during install—retracts when door closes• Showed simple method to automatically track the blade—no user adjustment• Improved fence—adjusts for blade drift “on the fly” while scale remains accurateDesigned easy to use router jig for mortise and tenon joint—well receivedCreated pocket hole jig—automatically adjusts for wood size, shows screw length

Designed and led engineering projects for power tools, putting them into production. Developed quote packages for new designs. Implemented cost reduction projects.Created Omnijig Joinery System™—large 16" and 24" router-based dovetailing jigs• $2 Million sales in tricky economic environment—old Omnijig only $0.5 Million• Eliminated repeated set up of standard joints—expert craftsman David Marks declared that the new Omnijig had obsoleted an episode from his TV series• Gargantuan effort for one engineer—released 692 parts and assemblies—many drawings with Geometric Dimensioning and Tolerancing (GD&T)• Mimicked narrow pins of traditional hand cut dovetails—fooled a hand tool expert• Created a versatile joinery station—variable-spaced through and half-blind dovetails, sliding-tapered dovetails, variable-spaced box joints, miniature dovetails• Reduced steel in clamps by 75% using theory and Finite Element Analysis (FEA)Designed 4200 series dovetail jigs—small 12" router-based dovetailing jigs• Industry recognition: “Best Buy” in American Woodworker, “Best Tool” and “Best Value” in two Fine Woodworking reviews, “Best Value” in Wood Magazine• Reduced user setup complexity—joints are cut without any measuring• Increased versatility without adding cost: one template for both sliding dovetails and half-blind dovetails; one template for both through dovetails and box jointsCreated door hinge mortise template—overcame patent—solved application problemDeveloped cost savings projects on 10" miter saw—$600,000 annual savingsConceived magnetic starter test—reduced test time from two months to two weeksTore down 106 models in 39 weeks for cost reduction ideas—2.7 models per weekCoordinated projects with marketing department, supply chain management, industrial design group, Asia manufacturing group, and multiple suppliers

Performed or delegated all mechanical engineering efforts for Blue M industrial ovens.Quoted and designed engineered-to-order ovens• Generated customer quotes with material cost and engineering hours• Created bills of material (BOMs) for special engineered-to-order ovens• Designed sheet metal parts and specified purchased components• Delegated design—provided drawing lists and basic dimensions to draftsmen• Created innovative solutions—450-lb, horizontal door opened with 10-lb forceConverted old engineering data to format of new facility• Imported over 450 BOMs for 24 configurable and 14 non-configurable models• Developed Microsoft Excel macros—BOMs converted quickly and accurately• Led team that converted over 5,000 drawings—from mostly hand drawings—created sheet metal form views and programmed blanks for automated punch press• Developed sheet metal bend allowance spreadsheet for draftsmenCoordinated designs among engineering, fabrication, assembly, and sales teams

Generated projects to improve the cost and quality of dishwashers. Communicated status at reviews. Coordinated with manufacturing, marketing, and purchasing.• Saved the company $500K in 1999, $1M in 2000, and $1.3M in 2001• Improved component life with reliability tools—awarded GE Reliability Practitioner• Designed and modified: many plastic parts, water jet nozzles, hydraulic system components, electronic and mechanical controls, sheet metal barriers• Qualified new motor supplier, led projects on rotating seals• Designed, constructed, and operated test fixtures, including controls and sensors• Designed pneumatic tools for assembly line—eliminated ergonomic problems• Six Sigma green belt certification May 2000; Energized Employee award, Nov. 2000

Direct aide to senior executive (general officer equivalent). Ran administration of 180-person organization. Managed performance-rating system for 43 personnel. Reviewed 80 promotion packages per quarter. Organized executive’s meetings and ceremonies.• Fixed broken performance reporting system—rework rate reduced from 120% to 20%• Developed excellent tools for reviewing performance reports—requested by peers• Harmonized communication across 7 divisions with content of weekly staff meeting• Facilitated move of 100+ people and equipment to new building—2 weeks early

Managed programs in the Air Force Acquisition Management process for the B-1B bomber, including $10 million Live Fire Testing and Evaluation. Held Secret clearance.• Created several briefings for senior Pentagon and State Department officials• Co-authored and reviewed test plans and test reports created for Congress• Coordinated efforts of major contractors, test labs, simulation experts, and others• Dealt with international treaty for test article—action prevented international incident