Mechanical Engineer Injection Molding

Cyril Kalache

Cell: 1-914-***-****

Email: ********@*****.***

Address: * ******* ***** ****, ********, NY, 10528 Computer skills / Languages

Software Skills

Solidworks

o Simulation (FEA)

o Motion (Kinematics & Dynamics)

o Floworks (CFD)

o TolAnalyst (Tolerance stacking)

Pro\Engineering Wildfire \ Creo Parametric

Ansys Workbench (FEA, Kinematics & Dynamics)

Moldflow (Injection molding)

Moldworks (Mold design)

Cfdesign (CFD)

Catia Speos addon (Light Simulation)

Abaqus (FEA)

Microsoft office products (Excel, PowerPoint, Outlook, Word) Work Experience

Generics (Start-up) – Beirut, Lebanon\UAE (Dec 2015 – Present)

Senior Mechanical Engineer Startup Company releasing a high end custom fit earphone to the market.

Concept Design, Prototyping, DFM, Mass production. Utilizing software

(Creo Pro-e & Solidworks)

3D printing utilized to make a silicone earfit generated from 3D data received of customers inner ear geometry. Utilizing Moldflow software to simulate injection of silicone into 3D printed plastic molds.

Used several manufacturing process to make an earphone assembly. Product is composed of, metals, plastics, and rubber parts. (Metal extrusion, Plastic Injection Molding, Overmolding, CNC, Lathe)

Generating BOM, Variants quantity orders, GD&T Tolerancing, project schedule management

Sent on trips to China, to choose suppliers and manufacturers.

DFM studies implementation product manufacturability & assembly streamlining. Project costs

(Tooling, part cost, lead times, verifying engineering samples).

Constant follow up with partners in China to bring concept to mass production of earphone Spoken and written Languages :

English

French

Arabic

Examples of previous work,

available upon request

iRobot – Bedford, MA (Sep 2013 – Sep 2015)

Senior Mechanical Engineer

Provided mechanical engineering analysis, design and documentation for autonomous video conferencing robot (Ava 500) and home robot products (Roomba).

Introduced different manufacturing methods to lower part/tooling cost. These include injection molding, Aluminum casting, machining, sheet metal etc. Met with suppliers and manufactures to determine which candidate would achieve the quality and cost that we are after.

Parts and assemblies designed include: Cosmetic surfaces CAD design, complex dynamic mechanisms, electronic component packaging etc. Software’s include (Solidworks, Creo Parametric PRO-e)

Performed FEA analysis and CFD simulations to insure parts and assemblies met product requirements. This included testing fixtures and rapid prototyping (SLA, SLS, FDM) techniques were used to qualify new designs. GD&T Tolerancing

Coordinating with contract manufacturers, suppliers, tool makers while maintaining scheduled design deadlines.

ULC Robotics – Bayshore, New York 2011 – 2013

Mechanical Engineer Consultant

Consultant on projects (Pipeline Robotics) being designed for Con Edison of New York City.

CFD simulation consultant for Robots being utilized in steam piping applications.

Pre-production CFD simulations were performed to optimize cooling of an underground robot, subjected to extreme heat conditions; (Heat transfer, fluid dynamics)

Optimizing flow of refrigerant through CAD modifications and CFD simulations. (Solidworks, Floworks,)

Dynamic robot simulations moving through pipeline to assure mechanical functionality in pre- production.(Solidworks Motion, kinematics & dynamics) Methode Electronics – Beirut, Lebanon (2010 – 2012)

Mechanical Engineer Designer

Lead designer for R&D and production stage projects.

Packaging designer for automotive sensors & devices (Microswitch, brake wear sensor, steering wheel paddle shifters & console buttons.)

Managing project timeline & design direction with suppliers, Tool makers, Methode US, Methode EU, Methode Malta production plant etc.

Issuing 3D designs, 2D drawings, FEA analysis, Dynamic motion simulations, moldflow plastic injection analysis, Tolstack calculations for 500,000+ production components.

Support for other projects in areas of analysis, simulations, calculations etc.

Used Pro-E and Solidworks to model assemblies and drawings. General Packaging Industries - Beirut, Lebanon (2009 – 2010)

Mechanical Engineering Designer

Managing a new plastic cup sheet line by designing and implementing cost efficient and mechanically reliable parts utilizing CAD, FEA, and CFD software.

Analyzing the reliability and life expectancy of parts and assemblies by utilizing.

Monitoring the progression of the sheet line from the design to the manufacturing process to ensure efficiency in the production of parts.

Responsible for the assembly of the new sheet line, ongoing modifications, follow up, and maintenance to ensure a proper production process.

Used Pro-E and Solidworks to model assemblies and drawings. W&M Sprinkler – Hawthorne, New York (2007 – 2009)

Mechanical Engineering Designer

Designed the sprinkler system layouts for businesses and residential buildings in New York City and its surrounding suburbs i.e. Metropolitan Museum of Art, Condominium buildings in Roosevelt Island, etc.

Executed hydraulic calculations for each task to ensure compliance with New York City fire protection codes, while also coordinating with architects to ensure the accuracy of plans and drawings.

Travelled frequently to on-site locations to ensure the implementation of the plans were completed accordingly.

Used AutoCAD to model assemblies and drawings.

Educational Background

Fairfield University

Fairfield, CT

B.S. in Mechanical Engineering

Graduated May 2008

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