Todd Durham Email and Phone Number

While working at General Atomics, one of my main projects was to use DfAM and FEA-driven design to change a part manufacturing method from composite to FDM additive. This manufacturing method change resulted in increased part performance and cost reduction of an estimated 40%. Another project was utilizing AM to design and manufacture a custom shop aid in 2 days to improve quality and consistency of a production part. I also conducted a failure investigation for process improvement of a… Show more While working at General Atomics, one of my main projects was to use DfAM and FEA-driven design to change a part manufacturing method from composite to FDM additive. This manufacturing method change resulted in increased part performance and cost reduction of an estimated 40%. Another project was utilizing AM to design and manufacture a custom shop aid in 2 days to improve quality and consistency of a production part. I also conducted a failure investigation for process improvement of a production part to reduce scrap rate and began development of a Technical Data Package for GA-ASI's FDM suppliers. Show less

Supervised and managed the NIU Makerspace, an additive manufacturing resource on campus where faculty, staff, and students have access to many 3D printing methods and consultation with the lab workers. The available methods include FFF printing on multiple Prusa and Creality printers, SLA printing with a Formlabs Form 2, and SLS printing with a DTM Sinterstation 2500+. Various projects include metal AM consultation with Radmax, 3D scanning and printing for McHenry County Historical Museum… Show more Supervised and managed the NIU Makerspace, an additive manufacturing resource on campus where faculty, staff, and students have access to many 3D printing methods and consultation with the lab workers. The available methods include FFF printing on multiple Prusa and Creality printers, SLA printing with a Formlabs Form 2, and SLS printing with a DTM Sinterstation 2500+. Various projects include metal AM consultation with Radmax, 3D scanning and printing for McHenry County Historical Museum Society, and consultation with Cronauer Law. Show less

In this role with the NIU Rover Team, I managed the team's budgets and orders along with reaching out to industry companies to maintain communication with our current sponsors and new sponsors.

I led the multi-disciplinary student organization to design and manufacture a Mars rover for the University Rover Challenge. During this time, I was responsible for budget and order proposals, technical writing for the competition's application process, and maintaining communication with companies for current and new sponsorships. I also organized outreach participation in events such as NIU STEM Fest and sponsor facility visits.

Led a 4-engineer team tasked to redesign the robotic manipulator for the NIU Mars Rover using Solidworks to minimize weight while increasing efficiency. The Fall 2017 semester was spent researching and designing the arm assembly in Solidworks and the Spring 2018 semester was used to manufacture and prototype the final design. I gained manufacturing experience by using a water jet, mill, lathe, etc. to machine the parts required for the assembly.

Integrated a Concept Laser mLab Cusing R Direct Metal Laser Melting (DMLM) machine into the current aerospace and laser precision welding business by developing written operating procedures, safety protocol, and similar documentation for metal laser PBF NADCAP accreditation. Also began development of a custom parameter database for production capabilities.

Worked alongside lab technicians conducting lab testing for air flow, unit torque, axial and radial runout, endurance and overspeed testing in addition to modifying and assembling test units to allow for rapid prototyping while maintaining authenticity of recorded data. Also completed individual projects such as redesigning the R&D lab layout to improve effective space usage and efficiency, digitizing engineering records, and worked with the engineering teams for reorganization of test unit… Show more Worked alongside lab technicians conducting lab testing for air flow, unit torque, axial and radial runout, endurance and overspeed testing in addition to modifying and assembling test units to allow for rapid prototyping while maintaining authenticity of recorded data. Also completed individual projects such as redesigning the R&D lab layout to improve effective space usage and efficiency, digitizing engineering records, and worked with the engineering teams for reorganization of test unit storage. Show less