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Injection Molding Engineer

West Bloomfield Township, Michigan, United States
February 26, 2018

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**** *********** *, **** **********, MI 48322 Telephone: O 248-***-****

H 248-***-****



Extensive progressive experience in working with engineers, designers and technicians. .

Particularly effective in conceptualization and implementation of new products into the marketplace.

Diversified in product engineering, manufacturing, testing/evaluation, engineering sales and all cost estimates that are in support of purchasing and benchmarking activities in the

automotive industry.

Innovative strategist who recognizes and acts upon opportunities to build the bottom-line.

Excels at cost cutting and increasing productivity, while maintaining total quality focus.


NICKADONI (West Bloomfield MI) Jan 2015 – Present)

Senior Mechanical Engineer

• Excellent oral and written communication skills, cost estimation as well as VA/VE activities.

Optimized the eight speed (GM/FORD) transmission concerning the parking gear and clutch

housings by significantly reducing mass (12lbs/assembly) and NVH issues.

Direct programs concerning vehicle Electrification. Developed Flexible battery cells, modules and

assemblies with significantly increased volumetric efficiency (concerning the active material) as well

the battery assembly energy density. This reflects to large objects packaging optimization, (injection

molding techniques), heat transfer phenomena and under the hood environment. (Patent Pending)

Worked on battery robust attachment techniques. (Patent pending) (Bosch Battery Systems).

Direct programs for the design development and integration of vehicle differentials, gear trains and

transmissions for traditional as well as electric vehicles including NVH issues and NVH (suppression methods) (McLaren Industries). Interfaced with major domestic OEM’s and worldwide market.

Knowledge of automotive Electrical Electronic Systems Engineering (EESE) products including

Electrical Center Assemblies, Harnesses Assemblies, housings and each of their related components

Extensive Assembly line experience concerning first time quality.

Product Design & Engineering experience for EESE products and their packaging

Excellent Interpersonal skills, time management and work prioritization skills

Martinrea LLC Troy, MI (June 2010 – Dec 2014) Senior Engineer

Suspension System technology, mechanisms, materials, NVH issues and suppression characteristics,

supplier certifications, manufacturing and group strategies directed towards material cost estimation

and cost reduction programs. Extensive launch issue management/resolution experience; conducted

DFMEA/DRBFM (Design Review Based on Failure Modes/Test Results)/DVP&R completed on time

and include requirement driven ADV plans. Work experience with automotive heavy machinery,

(suspension stampings, control arms, suspension brackets, motor mounts, and chassis rails).

Also with vehicle body enclosures BIW, and variety of steel grades (HSS, AHSS and ADI) for

stamping as well as casting applications and injection molding activities. Constantly interfacing with

the vehicle dynamics group (wheel behavior) by using extensively CAD/CAE tools. Applied DFSS

principals in all design activities. Conducted PPAP activities representing the product DRE.

Axletech International Troy, MI (Jan 2006 – June 2010)

Technology development/Senior Engineer

Direct programs concerning the redesign and development of products for the Control and Stability of Ground Vehicles, off road solid axles, Independent suspensions integrated to planetary wheel ends, heavy duty high articulated suspensions incorporating high steering angles for military applications and suspension designs to perform in vehicle blast. Steering column assemblies (IP integrated) with multi-function switches, sensors and high voltage plugs incorporating safety attributes, EMI suppression and injection molding. Extensive experience in the design development, integration, testing/evaluation of diesel engines, (castings, machining, dimensional stability and corrosion testing), drivelines, gear trains and transmissions for military wheeled and track vehicles. Supported prototype and plant builds; issue management from problem definition-root cause-solution-implementation-validation-feedback. Work experience with vehicle body enclosures, BIW and variety of steel grades (HSS, AHSS and ADI) for stamping as well as casting applications.

Includes design, development, implementation of suspension brackets, control arms, motor mounts and chassis rails following DFSS principals. Used advanced stamping techniques in order to avoid welding activities.

Active Suspension System technology mechanisms, NVH characteristics, materials, injection molding applications, supplier certifications, manufacturing and group strategies directed towards material-labor cost estimation, cost savings and cost reduction programs.

Inventor of the “Air spring/strut assembly” tested/evaluated on military vehicles for over 50000 miles including NATO double lane tests. Patent number 7,954,792.

Tower Automotive Novi, MI (July 1999 – Jan 2006)

Product Development Leader

Direct programs concerning the redesign and development of products for the Control and Stability

of Ground Vehicles. Includes design, development, implementation of control arms, suspension brackets, motor mounds, chassis rails, NVH issues and NVH suppression techniques following DFSS principals. Used advanced stamping techniques in order to avoid welding activities. Work experience with vehicle body enclosures, BIW and variety of steel grades (HSS, AHSS and ADI) for stamping as well as casting applications and injection molding parts.

Extensive launch issue management/resolution experience; conducted DFMEA/ DRBFM/DVP&R completed on time and include requirement driven by ADV plans. Extensive material-labor cost and process estimation activities

Work experience with heavy duty automotive machinery with continuous use of CAD/CAE tools.

Extensive Assembly line experience as well as VA/VE activities.

GM Automotive Systems Lockport, NY (February 1989 – July 1999)

Program Manager/Senior Engineer for Hybrid/Fuel Cell vehicles

Managed programs for the recently formed Advanced Technology Group, working on future concept applications concerning hybrid/fuel cells vehicles thermal management systems and cockpit modules integration.

Lead engineer for vehicle cockpit design/optimization activities. This included IP position with respect to the driver H point, controls accessibility while keeping eyes on the road, and driver ergonomics concerning control buttons location. Flow stratification studies were conducted concerning the flow direction from the HVAC IP registers to the driver face. Also, safety issues were considered for the rapid defrosting activity of the front wind shield. Designed built and tested/evaluated versatile cockpit simulator where various interior designs could be analyzed. The IP/Cockpit functionality as well as the design theme esthetics were constantly evaluated. Benchmarked over 100 IP designs. A variety of HVAC architectures were packaged for high efficiency systems. Patent number 05163302.

Also, familiar with vehicle geometry (aerodynamics) and interior architecture affecting the air flow towards the passengers. Worked on vehicle materials influencing the solar absorption/ reflection for hybrid/fuel cell vehicles as well as NVH suppression characteristics.

Developed tested/evaluated IP concepts (using magnesium alloys) and (injection molding) by integrating the HVAC assembly for an efficiency improvement of approximately 17%.

Designed advanced air bag concept (IP incorporated) for out of the position passenger location.

Designed/tested/evaluated single car cross beam for maximum structural integrity, lower cost as well as power steering column and pedals integration.

Responsible for the design, development and implementation of automotive climate control HVAC modules (injection molding) and compressors for high efficiency hybrid/fuel cell vehicles.

Utilized advance materials as well as rapid prototyping techniques through virtual prototyping and paperless design including NVH suppression characteristics.

Managed a staff of 27.

Hands on experience in releasing (DRE) vehicle thermal management components and systems for hybrid/fuel cell vehicles.

Extensively conducted laboratory testing on A/C compressors, water pumps and heat exchangers (radiators, condensers, evaporators, oil coolers as well as HVAC units) for hybrid/fuel cell vehicles. Patent number 6,499,954 B1

Participated in HVAC module designs for various platforms including performance attributes and vehicle system integration for hybrid/fuel cell vehicles. Patent number 05163302.

Led all design, development and implementation of automotive hydraulic pump assembly for automatic transmissions for traditional and non traditional vehicles. Patent number 05380167.

Laboratory testing on integrated thermal and climate control systems concerning vehicle performance in thermal wind tunnels and test facilities (GM DPG Arizona Proving Grounds) for hybrid/fuel cell vehicles. Patent number 5557845.

Participated in vehicle battery assembly thermal management testing concerning very cold climates as well as hot, high humidity environments (San Padre Island) for hybrid/fuel cell vehicles.

Very familiar with laboratory and vehicle instrumentation for data acquisition and data reduction techniques.

Designed state-of-the-art high efficiency climate-control systems with minimal environmental impact and negotiated a $35 million Japanese contract. (GM EV1, GM hybrid/fuel cell vehicle)

Directed an $11 million, 4-year GM/DOE project, completed on time and within budget for the electrically driven climate control compressor for the GM Hybrid/Fuel cell vehicle.

Very familiar with electromechanical systems integration, inverter technology and under the hood environment.

Bell Aerospace Textron Buffalo, NY (May 1987 – January 1989)


Supervised the development of the missile navigation system for the Trident Submarine.

Led a group of engineers, software developers, lab technicians and machinists.

Developed and maintained contacts with assigned supplier manufacturers, including purchasing, production engineering, advanced engineering, quality inspection, design engineering and product planning personnel of established customers.

Exceeded delivery dates 70% of the time (considered exceptional in the Defense industry).

Accountable for $500 million in contracts, including managing P&L, A/P, A/R, operations and R&D.

Executive Engineer (April 1984 – May 1987)

Led matrixed teams in strategic design for ground as well as aero vehicle dynamics.

Designed/tested/evaluated advanced suspension systems for prepared and unprepared terrain.

Also worked on new business development, strategic planning, sales and marketing.

Participate in training to maintain product/process expertise and ensured that the supplier base is knowledgeable of the latest manufacturing processes.

1983-1984 NATO Navy – Naval Attaché

NASA – Engineer (1979 – 1983)


1981 University Of Notre Dame MSAE

1979 University Of Detroit MSME

1978 University Of Detroit BSME


Executive leadership, Finance, Strategic Business Planning and HR. Very familiar utilizing CAD (Unigraphics, Pro E, Catia etc.) and CAM (paperless design), FEA techniques linear-non linear (NASTRAN, ABACUS), Microsoft Office Word, Excel, Power Point etc. Also QS/ISO 9001 Synchronous Engineering, APQP stage management process, GD&T(I,II), DFM, DFA, DFMEA, DVP&R, WEIBULL statistics, Lotus Notes, Problem Solving and Design of Experiments, Six Sigma, (Green belt), Engineering and Design Appropriation Request, Coaching for Superior Performance, Project Management for Engineers, and other manufacturing/technical/ management topics.

Twenty three U.S. patents.

Martinrea International (June 2010 – December 2014)

Axletech International (January 2006 – June 2010) (Lack of work)

Tower Automotive (July 1999 – January 2006): Went out of Business

GM Automotive Systems (February 1989 - July 1999): Moved to MI-Wife is from the area.

Bell Aerospace Textron (April 1984 - January 1989): Out of business.

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