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Work Background
SafranSenior Mechanical Design Engineer
Dec. 2022California, United States
Maverick Space SystemsMechanism Design Engineer
Jan. 2021 - Nov. 2022San Luis Obispo County, California, United StatesDeveloped complex launch separation systems for Smallsat, CubeSat, and ESPA class satellites ranging from 6kg to 400kg. Designed and analyzed advanced mechanical systems for high vibration environments. Implemented first-to-market vibration damping mechanisms to allow for sensitive payloads to be used in rideshare style satellites. Developed and managed supply chain including enhancing supply chain robustness and cost reductions while maintaining ITAR and DFARS compliance. Implemented and trained employees on best practices for lean-6 Sigma business and production practices including implementing continuous improvement, DMAIC, 5S and waste reduction.
I.M. Bohannon Mechanical DesignFounder/Engineer
Dec. 2020
SafranLead Mechanical Design Engineer
Jun. 2013 - Jan. 2021Santa Maria, CaliforniaDeveloped and designed components and assemblies on multiple airline seat programs while managing the tasks and workloads of a small engineering team of 4 to 6 engineers. Specializing in polymer component design, injection molding, vacuum forming, composite crush core and layup. Worked with a team of 6 engineers in Wales, UK for 5 weeks consulting engineers, quality inspectors, and assembly operators while transferring a program that was designed in Santa Maria and being built in Wales. Specialized in Injection Molded component designs, taught multiple training classes and consulted Design Engineers on proper design features and industry standards. Supervised numerous lean projects to improve manufacturing and team efficiencies. These projects include implementing new ultrasonic staking processes, developing tools to improve visibility between test engineers and design engineers, and refining processes to help manage the program development teams. Worked closely with the manufacturing floor to resolve issues with design and manufacturing, while developing new company standards for future programs. Designed numerous components from materials such as FAR qualified plastics, fiberglass/honeycomb composite panels, layups, and crush cores, as well as aluminum and stainless steel machined and stamped components. Worked closely with Certification, Stress, and Flammability engineers to ensure seat shells met strict customer requirements, as well as FAA and EASA requirements.
Purdue Solar RacingChief Engineer
Aug. 2012 - Jan. 2013Designed and Build solar powered race vehicle aimed to achieve maximum MPGe efficiency.
Optimized Carbon Fiber Body and Chassis designs. Reduced chassis weight to less than 150 lbs while maintaining overall stiffness with CF/Nomex panels.
Performed FEA on Carbon Fiber Composite chassis using ANSYS 14.0 and CATIA’s Structural Analysis package.
Developed Dynamic Suspension system using Rear Swing Arm and A-Arm suspensions, reducing packaging, while maintaining Roll Center.
Performed Layup of Nomex and Airex Coring composites using Vacuum Forming technique.
Nidec Motors and Controls/Mallory AutomotiveDesign Engineer Contract
Aug. 2009 - Aug. 2012Indianapolis, Indiana, United StatesContract position during college totaling 24 months
Performed Design Validation and Production Validation tests for GM Centerbank Switch units.
Analyzed GM warranty returns and implemented assembly plant corrections for Thin Touchpad Switches, Rotary Headlamp Switches, and Stoplamp Switches.
Consulted and improved assembly plant epoxy adhesion processes for new Touchpad and Centerbank units.
Designed and tested Centerbank console Switch units for Large Utility Trucks for GM’s K2xx program.
Developed patented waterproof remote control device for Jacuzzi-Sundance Spas.
Integrated GM Teamcenter PLM submittal procedure into design process.
Improved waterproof, side-mounted User Interface device and remote control for Jacuzzi-Sundance Spas.
Designed electronic housings and control interfaces for multiple Pool Pump devices for large commercial and industrial pools.
Created engineering test procedures for waterproof Jacuzzi-Sundance remote controls and User Interface units.
Purdue Solar RacingMechanical Director
Aug. 2009 - Jan. 2010Developed and improved group communication by encouraging Concurrent Design approach between interdisciplinary teams.
• Engineered test rig to measure and reduce tire rolling resistance. • Built lightweight, High Efficiency Steering Linkage design utilizing Al-6061 and weighing less than 6 lbs.
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