Barry W. Carothers

214-***-****

acryu4@r.postjobfree.com

PROJECT ENGINEERING

Mechanical Design/management

Summary of Qualifications:

18+ years’ experience providing mechanical engineering to Commercial, Military & Aerospace markets including product design, installation, manufacturing, and MIL-STD verification testing. (Previous DOD clearance)

Design responsibilities include product definition, full concept design/layout, design specifications, Optics packaging, Optics alignment & testing, Electro-mechanical packaging, medical equipment, tooling, risk analysis, CAD creation, design validation, regulatory submissions including UL(electrical) and ROHS, Scheduling, and presentations.

Manufacturing responsibilities: complex device assembly, tooling design, assembly process instructions, guidance on procurement, fabrication, quality, and successful sourcing. Manufacturing support for scale-up, production start up for test markets thru mass production launching and Machine Shop and Prototype Equipment/Processes.

Technical Writing in various capacities including proposals, patent applications, technical procedure manuals, FDA research, Reports, work instructions, assembly processes, and testing procedures for both MIL-STD and ASTM. Provided Concept graphics for military proposals

Testing Responsibilities include product design verification, safety, reliability, effectiveness, feasibility, and functionality. Developed and monitored testing protocols. Responsibilities Include interpreting data to make sound technical recommendations on product and process issues.

Education

Le Tourneau University, Longview, Texas

BS, Mechanical Engineering 1994, ABET

Pro/Engineer Wildfire 5.0 CREO (20,000hours+)

SolidWorks 2012+ (5800 hours), PDM/Intralink

GD&T, ASME Y14.5M-2009

Areas of Knowledge

Opto-Mechanical Systems ● PLASTICS/composites ● Electro-Mechanical Housings

Testing Protocols to meet UL/environmental specs ● Excellent Communication Skills ● Machine tools

Structural Design (FEA) ● Tooling/Fixture design ● Technical Writing

Test Equipment ● Sheet-Metal ● Root Cause Analysis ● Mechanisms ● Troubleshooting

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Professional Experience Summary (Contract/Direct)

PRG Lighting, Dallas TX 2014-current, 2011-2012

Electro-Mechanical Engineer:

Took existing World Class optics/lighting products and made design enhancements to increase dependability, functionality, and manufacturability. These complicated Opto-mechanical assemblies have structurally sensitive parts with tight alignment. Created Optics & electro-Mechanical Packaging and developed fixtures & tooling. Specified materials and performed testing of new part designs. Heat Sink Designs for LED mounting and cooling. Created and sourced CAD drawings to vendors and inspected parts. Extensive Plastics and housing design. Worked with Vendors and Sales Team

Elbit Defense Systems, Fort Worth, TX 2/2013to 4/2014

Mechanical Engineer:

Engineering Design support for optical guided munitions (smart bombs) programs for military customers. Packaged tight tolerance optics systems using metal and plastic parts. Designed various parts/assemblies and performed layout analysis; Packaged electronics as well. Additional design responsibilities included design and development of Unmanned Air Plane launch mechanisms to provide stable launch systems for launch from Unmanned Boats. Gave presentations at High level meetings. Managed Projects.

Broadstar Engineering, Dallas, TX (Pro/E Wildfire 5.0) 2012

Aerospace: Studied/Applied fluid patterns, power requirements, & design load cases/methods in IEC 61400. Created mounts for electrical components and performed verification testing. Structural design, tooling creation of enclosures, bezels, and plastic/metallic parts with tight tolerance alignments. Mounted control equipment and developed testing procedures. Created detail drawings/tooling req’s and critical interface Req’s. Specified hardware & Created BOM’s.

Crane Aerospace, Wireless Monitoring Solutions Dallas, TX 2006, 2008-2010

Electro-Mechanical Engineer/Manufacturing support

Full mechanical design/R&D of small Electro-mechanical devices for commercial/military customers. Included oversight to meet product Design specifications and UL/ROHS testing & specifications adherence. Material shielding adherence to pass tough UL Electrical requirements

Included full product design for production, assembly structure, installation tools, styling, part design, human factors, Electronics Assembly, testing protocols (product specs).

Testing: Set up Testing Protocols for product validation/internal verification: including materials research and environmental, longevity requirements. Develop Test Procedures (reliability, functionality) and monitored outside performance testing to meet product specifications

Manufacturing: Raw material selection, assembly/production process, work instructions, guidance on procurement

Texas Instruments Dallas, TX 2007

Opto-Mechanical Engineer:

OPTO-Mechanical packaging design: Packaged TV electronics/ optics using injection molded plastics. Tight tolerance parts and optics positioning. Built Optical fixtures. Thermal Design

Electro-Mechanical design. Created bezels, enclosures, and test equipment

Structural Design: Mounting Scenarios. development of overall product layout (Pro/E)

Created Pro/E drawings and used GD&T. Created PowerPoint Presentations.

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Professional Experience (Continued)

BAE Aerospace/Lockheed Martin Owego/US Army 3/01-11/06

Lead Mechanical Design Engineer/Technical Writer:

Complete Re-Design military cargo beds to meet US Army Specs. 40% weight reduction/ 20% Cost Savings. Included heavy composites design/integration, design to meet armored systems requirements (IED, Artillery rounds) of TACOM, weapons mounting design and assembly. Oversight of testing and assembly at Aberdeen Proving Grounds to meet schedule requirements.

Technical Writer military proposals: including concept design/proposal write-up of military products. Wrote all assembly procedures and created full concepts/graphics. Met MIL-STD requirements

Raytheon (Defense Systems) Dallas, TX 1999-2001

Electro-Mechanical Engineer:

Electro-mechanical Packaging and tight tolerance part design for Uncooled Infrared Systems

Worked with Vendors and tooling manufacturers to solve relevant problems.

Optical-mechanical packaging/tight tolerance design: Design of optics housings/ focus mechanisms for LTWS FLIR Weapon site to meet military specifications with emphasis on functionality. Included lightweight/high strength structural Plastic components and tight tolerance optics/electronics packaging

Performed extensive injection molded plastics/structural design. .Pro/E drawings/GD&T

Technical Writer: Assist in design and graphics of a low power un-cooled infrared weapon site. Technical research to meet specs.

Peterbilt Motors Company Denton, TX 1994-1998

Mechanical Engineer:

Development of commercial truck front hood pivot system, front and rear hood suspension system, hood tilt assist mechanism, and hood opening/closing dampening system. Wrote Patents. Solved installation issues and assembly issues for the assembly plant.

Worked with manufacturing to implement designs on full product lineup.

Worked with Sales Team and operations plant.

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