Engineer Design

RESUME'

Daryl Loren Lenhard

Field Contact Info

March 26, 2013

*************@***.*** Cell 248 470

3179

Contractor

*************@***.*** 33006 Seven

Mile Rd # 232

Home Western US Aero-space

development Livonia, Michigan

48152

Aerospace-Product, Composite/Metal Shop Fab Methods. Tool Design, Eng.

Support, Enovia LCA CatiaV5 MBD & 2D drafting,

Shop floor Engineering Liaison, Planner, Mfg. Eng. Technology-

Transfer, M&PT Methods, Room Cure & High Temp Epoxy

Tooling Systems - Cauls. Composite Certified on Navy & Air Force &

Boeing since 1981, Developer on Low observable "LO" (Stealth) carbon

graphite tooling since early 80's. Eng. from Concept, Mylar's, V5, Cad

Data, verify eng., design, write process, quotes, hire outside vendors,

support internal development. Validate engineering changes support

schedule. Respond to corrective action issues on multiple assembly

programs. ME Liaison to vendors, structures, machine & assy concerns.

Clean Room R&D, FAJ processes on Mil., Com., BJ, UAV & Spacecraft

applications. Write Process Methods to support Eng, Tooling &

Structural Assy.

Comforce 06/21/12- Boeing, Seattle Mfg Eng - ADC, Enovia, V5 MBD, 787-

9 H-Stab dev/support. DCAC Visiprize, NCM,

OWI, Unix, PDM /CAPP. ME -Liaison-Planner/Workflow & roper sequence

of Operations & sub-steps for specific procedures

to respond on NCR/NCO Tag Issues - Plan Author, Static & Fatigue for H-

Stabilizer, 4 - Developmental builds. FAA Conformance MRB, QAMRB

liaison intervention response working ADPP's-Assemble detail process

planning & IP- Installation Plans}. Shop Liaison, 70+ hrs per week.

Plan procedures for fabrication of related tools, shop equipment & ply

orientation on all repairs.

Polar Aero - 10/04/11-06/11/12 Mich., ME on Experimental 26' concept

vehicle design & build. Reverse engineering with 3"+ solid composite

core & epoxy skin. Structural build to withstand extreme temperatures.

Field test support for science & electronic equip. Built for future

North America Mil trade show exhibit. Canadian Corp / personal

investment, structural build. Hydrogen assist.

Noramtec, NY, 03/11/-08/11, Bombardier Montreal, CA Lear 85.

ME/Composite Science Technologist. Assisted on Composite,

Drill, Trim & Rout Guidelines & Composite Mold Tool Guidelines for AL &

Invar Tools. Designed support tooling for Mexico factory support.

Catia V5 MBD, develop detailed 2D drawing design for nose cone

transport, vertical & horizontal stab tooling. Checker

on 150+ Catia MBD, excel SS to correct tool design errors on ply layup

EOP & T/H locations. Process methods. Wrote Template

to write tool order for planner/vendor for composite parts. Guidelines

{19 pgs} hyperlinked to 730 pgs of Bombardier standards.

PDS Technical Service, WA 07/10-02/11, Boeing, Seattle. ME Composite

Technology Analyst, on aircraft & composite spacecraft nose cone

development. Sea launch communications satellite support. Boeing

Defense Systems, DCAC/Velocity system & also implementation support

on 787, M&PT. PDM, CAPP Lvl 4 support. Catia V5 on BDS multi projects.

BAC global documentation for MBOM {Mfg. Bill of Material} - EBOM {Eng.

Bill of Material}. UNIX IT Checker. Lap-top- cell provided by Boeing

for remote & field telecommunications. Supported Bellevue, Auburn,

Everett, Tukwila & Boeing Field, Proof of Concept. Primarily Sea-

launch

Rocket Nose-Cone vaulting of 1,800 items for PDM/Eng drawing & detail

review. Mfg Eng support to get program up & rolling.

Polar Aero Structures Corp 12/09-05/10 Cheyenne, WY based Corp. MI.

Design, R&D Product build, eng, scale model development of advanced

composite blended swept wing concept, UAV- Aircraft per NASA Cleveland

Conference 08/09. Mfg Eng. ITAR

Volt Technical Service, WA Boeing, Seattle, WA 06/09/07-11/20/09. ME Lead

Planner on Flight Test/ Probe/Duct Build, +

Calibration for 787, 777, 747-8, 767 P8A for Flight Test Ventilation

Systems. UNIX, ITAR, Enovia LCA/Catia V5 Checker on Eng. Liaison to

write 100's of Duct Plans for Flight Test. Dimensional sketches from Catia

V5 MBD. Analyze Machining & Shop floor concerns, Red Lined root cause

corrective actions for 30+ M.E.'s. Proficient in PDM, CAPP, ERP Software.

NCR's M&PT. Validate Final Approval of F.T. detail & composite assy's.

Review Eng. dwg issues in Redars. V5 2D drawings off MBD, clean-up Eng.

errors, ELR Process. Refined BOMs, wrote assembly Plans, Full A/C dev. &

composite support. Update Eng. at vendors. Burn lab / flight line. Al &

Titanium tools. 30 months,+ M.E. 2nd Shift Shop Liaison 3400+hrs/yr 26 on

2 off.

Planetechs 1st Article Process Development. on #1 787 Dream-Liner,

Composite/Titanium Sec 43 & Fuel tank dev. 01/07-05/07

Structures -Liaison Eng. / between KJI & FHI, Global Aeronautica,

M&PT/ME/Mechanic. Charleston, South Carolina.

Planetechs Chicago, Ill Modification in Taiwan, China LCF (Large Cargo

Freighter) LCF to carry the 787 Fuselage. From Sec 41

to Sec 47. Sheet Metal, Titanium, Doublers, Structures. Evergreen

Aviation Technologies Service. EGATS Swing Tail support, created

geometric layout on A/C to set avionics, cameras, hydraulics, stand-

offs, Electrical, Flight Control Details. Hands on

support Boeing AOG team build & Inspection. 747-400F Verify & update

eng for FAA. Visit H.K. China twice 09/06-12/06

Oxford International MA Pratt & Whitney MI..H.T. Composite Tooling

Consultant M.E., Tool Design. M&PT, Structures, Planning, Trim & Drill

Tools, Assembly Fixtures, Military - Commercial Aircraft. 747-400 Engine

Fixture Design, Overhaul & Repair. Tooling Process- Writing Procedures.

Engineer & build of Multiple Thrust Reverser Steel Holding Fixtures for

Repair. Conceptual design & development, hands on build per own design &

tool liaison on Cowls. Dev / machining done at vendor. F-117 Acoustical

Liner Tool. Established ground up build to "Net" Condition using standard

optics, Jig & Fixture Methods. Established. tooling quotes. Composite

blocker doors build process, supported titanium/aluminum tooling. 02/06 --

09/06.

Planetechs - Aerodynamics, Pontiac, MI. ME upgrading business aircraft

avionic modifications, antennas, sheet metal, black

boxes, navigation systems, com,, adf., nav., gps... etc. Composites.

Set up of Avionics lab, ME task. Writing technical process

on HIRF-(High Intensity Radiation Fields) Environmental Conditions &

Test Procedures for Airborne Equip using the RTCA DO-160E/EUROCAE ED-

14E. Fokker A/C . Lead avionic installations on aircraft per FAA

Requirements. 11/05-02/06

Lear Siegel, OK Hill A.F. Base, UT, B2 Complex. ME Composite Process

Dev. Planner A10's, Home vandalized 05/05-11/05

PDS Technical Service, Wichita, Ks Nordam, Tulsa, OK Thrust

Reverser's, Radom's, high temperature composite bonding

tools & hands on ME. Repair station. Com/Military, B-52.

Support composite, nickle & titanium tool applications. 12/04-

05/05

1099 Contract NOR-RAL Plastics, GA, 3/04-11/04 on Airbus General

Dynamics, High Temp Wing Fairing Tooling Fixtures build.

ME hands on build. Mock-up compound contours off EOP of OML surface.

Transfers off Masters, Composite

H.T. Bonding tools. Vacuum Bag Process. Estimated router & drill

fixtures design & bid. Declined direct Tooling Mgr position.

Contract Consultants, Bedford, TX BELL Helicopter, Hurst TX

ME- Loftsman, Originated 3 D tool design/photo templates,

design/build shop aids to support composite, titanium,

aluminum installations. Mechanical build support for V-22

Osprey.

Research, Plan & define engineering, Catia V5, 3D Space

Models, CAD data, wire frames, detail drawings. Design &

Build. Metaframe/Windows/Bedvue, Huey, AH-1 Cobra,+ 9/02-

11/03. 80-84 hour weeks. Blade & hub development.

ATS, Norwood, Ma. Aurora Flight Sciences Fairmont, WV -

NORTHROP (San Diego) contract on UAV Global Hawk

Unmanned Surveillance Aircraft. 1st Composite full & half

scale build for two Air Force models. Composite- UAV build.

Technical assistance on graphite composite build procedures

& vac. bag H.T. process methods. Mfg. Eng. 2/02-6/02

SMART Fla. BOMBARDIER-Global Express, Montreal, CA,

Completion Center hanger for 40 planes. Interior lofts,

Flight

Line. Composites. Loftsman - Layout install interior

sidewall shells of Kevlar overlays, windows/etc, per cad/eng.

5/01-11/01

NORTHERN TECHNICAL Thunder Bay, Ont. BOMBARDIER Montreal,

Engineering Support for CRJ700 Optics, In-house &

Vendor Field Support, Jig & fixture. Optics for plant

layout, Fuselage & Wing Fab. Challenger air control surfaces,

6/00-2/01

PDS Technical Service, RAYTHEON AIRCRAFT Wichita, KS

Jig/Fixture, Composites titanium, eng. support for corporate

jets.

Built main aft cabin jig for graphite fuselage structural

reinforcement's per Leica laser tracker/Optics. A/C build.

12/99--6/00.

PDS Technical Service, Tulsa, Ok NORDAM TX Composite

repair, air control surfaces, spoilers, nacelle, aileron.

Dornier, Delta,

Northwest, 727's. C-130's. Rebuild of air control surfaces

out of graphite/ sheet-metal construction. Composite M.E.

12/98-12/99.

GRANT PROPOSAL Personal invention research of advanced

composite compaction methods, Advanced Reusable

Space Transportation Technologies Research. NASA RA 8-21

(Advanced Space Plane Concepts- technical writing) 8/98-11/98

Chipton Ross, Manhattan Beach, CA NORTHROP GRUMMAN CA Plant

xx LO certified for B-2 Mod. block 30 Program.

H.T. Composites, A/C OML + Engine bay. Secret. Transfer

from Aircraft Division Hawthorn, CA PDS Tech. Costa Mesa

CA

Jig/Fixture, Composite Toolmaker / Developer. Worked AC

division pending Secret clearance. 1/98-8/98. Northrop

Grumman

PDS Tech. Wichita, Ks. RAYTHEON AIRCRAFT JPATS Military

Trainer. Jig & Fixture, optics, composite tool build.

7/14/97-12/97

CDI Ontario, Ca TRANS CONNTINENTAL AIRLINES Ypsi., MI Flight

line Repair Station. Reworked DC6, airframe, sheet metal

skins, stringers, circumferential. Leading edges, fuselage,

wing, composite air control surfaces. Inspected all

composites. 04/91-

B&M Assoc, San Diego, CA NORTHROP VENTURA DIV. Newbury

Park, CA Sr. Plaster Patten Maker, Tacit Rainbow, MX

Missile, Drones, F/A-18 Mod, Eng., T.D.-Cad, F-5, F-20 A/C.

Lead, High temp/room cure, Composite Process M&PT. 01/90-4/91

SUB-CONTRACTOR-1099 Brunswick Defense/Grumman/Douglas

Contract. Marion, VA Lead-Loftsman of 12, Master Layout

1st Graphite C-17 Air Control Surfaces /Flaps. Mfg. Eng.

Liaison to Grumman. Technical Writer, Process/Methods. 6/89-

12/89.

Eric Harrison LTD, Thunder Bay, Ont. Canada CANADAIR

AEROSPACE Montreal, Canada, Jig & Fixture. H.T. Composite

Tooling, M.E. Liaison on Airbus program. Sheet metal-

Inspection. Commercial Aircraft & fire bomber hanger. 1/89-

6/89.

B&M Assoc. San Diego, Ca NORTHROP AIRCRAFT Torrance, Ca

Plaster/Plastic Pattern Sr. Jig & Fixture, Optics,

H.T. Composite OML/IML Surface Development. F/A-18 Plaster

Master Model. 747 Tooling. Chem.- Mill & drill templates.

F-5, T-38, F-20, F-23 black hole + projects. Room Cure

Router Tool Dev. for Graphite Parts. Tooling, KB, K3, K2.

5/88-12/88.

TAD Technical Tukwila, WA HEATH TECHNA AEROSPACE Kent, WA

MAC C-17 Wing Fairing-Master Model build Jig &

Fixture, Plaster/Plastic Pattern Sr. Optics & Template set

up per cad, Tool Design & xyz Reference System. 11/87-

5/88

PDS Tech, Irvine, Ca NORTHROP ADVANCED SYSTEMS Pico Riviera,

Ca Plaster/Plastic Pattern, Jig/Fixture, B-2 Stealth.

High Temp Tooling, Optics/tool design, Eng./cad, composites.

Titanium airframe support. 8/87-11/87. 6.0 Earthquake.

TAD Tech. Salt Lake, UT. FLAMECO Engineering Ogden, UT Lead of

12, Bell V-22 Osprey Titanium Engine Nacelle tooling

Titanium formed 1767*F. Design/built helicopter blade

composite router tools, patterns, jig & fixture, optics, shop

liaison. 2/87-8/87

US Eng. Sherman Oaks, NORTHROP VENTURA Newbury Park, Ca

Plaster/Plastic Pattern Sr., F/A-18, F-5 Drones.

MX Missile fairing's. H.T., room cure composite bonding

tools, vacuum bag. R/D, Optics. Ti/Al metal form tools. 11/86-

2/87

.LPL Technical Huntington Station, NY GRUMMAN AEROSPACE

Bethpage, NY Master Template Layout per Eng. lofts, Cad,

Tool Design, Masters. H.T. Composites, Titanium Gulfstream

Nacelles. Built F-14 Tools, E2C, A6 Optics. M&PT 2/86-

11/86.

Personal Research 12/85-2/86 Orbital Transfer Vehicle OML

Study Relative to future NASA requirements for X-plane

technical

research. Fla., Huntsville. Invited to Rockwell Final

Assembly, in Palmdale, Challenger/Discovery Shuttles, via

White House/Reagan

silicon ceramics. Viewed Shuttle's principle build, & cargo

bay geometry- OTV development project toward star war's

concept.

HL Yoh, Tucson, AZ GATES LEAR JET Wichita, Ks

\Plaster/Plastic Pattern Sr., Jig/Fixture Composites, HT

Vacuum tool build

for skin location, set stringers, circumferential, per

tool design, eng, cad., optics. Sheet metal layout. Form-

blocks. 3/85-12/85.

PDS Technical, Dallas, TX BEECH AIRCRAFT Wichita, Ks

Plaster/Plastic Pattern Sr., Technical writer. Established

graphite

H.T. Composite Process Methods (M&PT). Tooling methods-

process for Star Ship Business Aircraft Program, R&D. 6/84-

3/85.

LOCKHEED CALIFORNIA Palmdale, Ca Plaster/Plastic Pattern

Sr., Tool liaison. C5B, P3 Orion. Worked off micro film,

hanger

produced drawings - photo templates.

Composite/Titanium/Al. Shop aid's to resurface tools for C5B

Galaxy per Eng. 2/84-6/84.

NORTHROP VENTURA Newbury Park, Ca Direct Plaster/Plastic

Pattern Sr., Optics, F-20 Fighter Jet, F/A 18 Fighter.

Drones, Radomes, Pylons. Composite Bonding Tools, SPT'S,

PFP'S, Jigs. Invar, Titanium, AL. Air Force / Navy. Developed

Advanced Experimental Materials Engineering process to apply

H.T. Composite Metal Matrix to lay-ups & proofed. 10/83-2/84

NORTHROP AIRCRAFT Hawthorn, Ca Direct Plaster/Plastic Pattern

Sr. Optic's, Jig & Fixture. Master model build, layout per

3 D CAD. Titanium/Al/Composite H.T. tooling, engineering,

loft F-5, T-38, F-18, F-20, Boeing 747, Air Force/Navy 12/81-

10/83.

Experimental Military, Commercial, Business Aircraft - Unmanned Aerial

Vehicles, Ground up Tooling Development on the following.

F-20 Experimental Fighter, F/A-18 Revision on up, F-5G, T-38, B-2 Stealth

Bomber, BQM 144 Target Drone, Tacit Rainbow Missile, MX Missile Fairings,

C5B Galaxy, P-3 Orion, Special Projects, F117 both at Northrop & Lockheed.

Black Hole projects at Northrop. B1B, Beech Starship Business Jet, King

Air, Gates Lear Jet GP180, Bell V-22 Osprey, AH-60, Black hawk, Raytheon

Premier Business Jet, A6, E2C, F-14 Tomcat, Gulfstream Business Jet, Global

Hawk high Ceiling UAV, Cobra Helicopter, C-17 Transport, C-130, MD-80,

Boeing 777, 747, Air Force & Navy Special Projects, Surface to Air Missile

Pylons, Bombardier Challenger, CL415 Water- Bomber, Global Express

Business Jet, CRJ-700, GE Special Projects B.H. Engine Exhaust, DC6, Delta,

Northwest, Mesaba C/D checks, B-52. Airbus, Dornier. F23 Black Widow for

McDonald Douglas / Northrop, Air Force Experimental High Ceiling Fighter

Jet. F-22 Raptor. Fokker F-28. Classified Advanced Projects, F-18 work in

Canada. X-29 segment. Rockwell Space Shuttle. UAV 747-400 LCF. 787-9,

777, 747-8, 767, P8A Poseidon Catia V5, Cleared to Draft military

Dimensional sketches per MBD - Shop & Inspection Ref. Boeing Mfg.

Development Flight Test Seattle, WA. Lear85 Methods for 2013. Lean

practices on programs, coordinate all data on Excel SS to support team

schedule.

Technical Writing/Process/Planning/ Composite Methods &Tool Design /

Mfg. Eng thru build-up to Completion. Service Support.

Honeycomb/ Metal skin composite bonded assemblies. From interior sub-

assemblies to high temp composite tooling support. Multi-faceted. Support

plaster model or CNC / mandrel development to room cure or high temperature

tooling & graphite part construction, vacuum bag/auto-clave process. Sheet

metal-/ honeycomb / structures, full helicopter, commercial, cargo and

military aircraft applications. Assist aircraft program certification

through building - FAA requirements, quality & close tolerance workmanship

to meet customer request. Composite hands on background from concept

through a variety of applications in full aircraft development. Metal

bonding to air-control surface actuators. Jig & Fixture Optics support,

engineering development on complex alignment jigs to complete assembly on

finished aircraft. MS Office, in-house computer systems, excel, PP. V5

checking to approve Tool Design, CAD, CAD Data, surface scanning per Eng.

MBD to match close tolerance objectives & design tooling for production .

Soft Tooling Impressions to match CNC profiling. Advanced Military

Fighter Aircraft / UAV & Commercial A/C & underwater interest. H.T Epoxy

Composite Liaison & Process Mfg Eng. Observed 1 Trillion+ $ spent in the

Advanced A/C Industry. Use of the Science behind the design, to isolate

engineering & proof. Take it to the next step per Customer unique

requirements. Edwards A. F. Base visits with Northrop, 80's. Opportunity

at Area 51 with Lockheed.

Member of Society of Manufacturing Engineer's, Dearborn, Michigan.

Certified ME Planner for Boeing 5 times, PDM, CAPP & ERP.

Aerospace/ Product Tooling Aircraft "Master Tool" Developer

Aircraft Planning, Soft & Hard Tooling, Part &

Assembly.

Mfg. Eng. Analyst Composite Process

Engineer Engineering Checker, Cad - Cad Data, 3D Root

Cause Analysis

Support Jig & Fixture, Optics Technical Process Writer M&PT

Loft-Master Dimensioning, Verify T.D. to Eng. on final

assembly.

Fabrication Build Support Tool Design, Excel, MS Word

Hands on - Helicopters, Missiles, Drones, UAV,

Blackhawk, A/C,

Advanced Composites Full Modification on Military

Jets Spacecraft, Standard Optics... XYZ, Canted Wing

development

Compression Mold-Tool Design Lieca Laser detail setting on Jigs

Geometric Dimensioning & Tolerance Theory. ITAR Compliant.

Auto Clave, PFP's, SPT's, Build Structures, Circumferential,

Stiffeners Stealth LO "Master" Development for OML. BIW Programs

Hand Calculations / Verify Eng. Tooling Engineer- MFG. Methods

Tooling Ball Reference System Tie in Eng. & back to CAD

data.

CAPP I-CAPP II, PDM BANN ERP REDARS Enovia LCA

CATIA V5 Drafting/ M.B.D. 2D Mechanical Design 5,500hrs++

Studied hovercraft/hydrofoil & Eng Build Technology @ U of M,

Engineering - mid 70's. Optic Cert. Northrop early 80's.

Over 95,000 Hours of Hands on Industrial Development. 18

experimental - prototype vehicle builds in Michigan 1974-

2012.

Secret clearance 1998, Confidential 30+, Reverse

Engineering. US Born Citizen, Detroit, MI.

Daryl Lenhard M.E.

Contractor/Developer, Advanced Design/Build/Mechanical

Technical Process Mfg Eng Planner.

248-***-**** Cell

Composite Tool Design Strategy - Jig/ Fixtures. Short-long term Aerospace

Developmental Contracts Passport. Single

Sr. Rate Considerations. Million miles+ traveled. Interested in Science

- Spacecraft support/build. *************@***.***

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