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Mechanical Engineer Design

Sunnyvale, California, 94087, United States
November 05, 2018

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Paul R. Overmyer

**** ***** ***** 408-***-****

Sunnyvale, CA 94087


Seeking a Mechanical Design Engineer position in a product development group based on:

20+ years of experience as a Mechanical Engineer in the semiconductor industry

Extensive experience with SolidWorks, AutoCAD and Inventor CAD systems

Proficient in Visual Basic to write computer programs for Windows

Developed CALC4CAD, a program that draws 2D gears, sprockets, ball bearings, fasteners, springs, isometrics, hole charts, graphs and steel shapes for AutoCAD

Used ANSI Y14.5 standards and GD&T to tolerance detail part drawings

Member at Tech Shop where I use laser cutters and 3D printers to prototype parts

Design Highlights

Wafer and chip handling products for the semiconductor capital equipment

Industrial cameras and mechanisms for machine vision and traffic solution industry

Designed parts and made prototypes using laser cutters and 3D printers

Career History

Mechanical Engineer, Kinetic Systems, Inc., Livermore, CA (contract) 9/17 – 11/17

Design of stainless steel enclosures for industrial chemical storage using SolidWorks

Responsible for creating design layouts, assembly and detail drawings for designs

Mechanical Engineer, Expo Instruments, Inc., Sunnyvale, CA (contract) 9/14 – 3/17

Design of plastic enclosures to be used in a liquid level systems using 3D CAD

Responsible for creating design layouts, assembly and detail drawings for designs

Used basic engineering calculations to determine deflections of parts under load

Worked with vendors to make tooling for a liquid level system for swimming pools

Made prototype parts to ensure that parts fit together and functioned properly

Mechanical Engineer, End-Effectors, Inc., Santa Clara, CA (contract) 6/09 – 6/14

Design of ceramic end-effector for 450mm silicon wafer using Inventor

Finite Element Analysis of the 450mm end-effector using Algor and Inventor

Design of custom ceramic end-effectors to meet customer specifications

Design of lapping machine to support production of ceramic products

Design of CNC laser marking machine for ceramic parts from an old mill

Wrote g-code computer files for marking ceramic parts on the CNC machine

Mechanical Engineer, JAI, Inc., San Jose, CA 6/07 – 3/09

Design new industrial cameras and enclosures using SolidWorks

Worked with JAI salesmen and customers to set specifications for cameras

Interface with vendors to produce parts per JAI, Inc. design requirements

Create new camera parts to replace older designs as a part of a cost cutting team

Design custom tooling to aid in the assembly of cameras and printed circuit boards

Support existing camera drawings done using SolidWorks and AutoCAD

Mechanical Engineer, OptiSolar, Hayward, CA (contract) 9/06 – 3/07

Designed new equipment for the solar power industry using SolidWorks

Interfaced with vendors to produce parts per OptiSolar design requirements

Created production part drawings for mounting structures of new PV installation

Created concept drawings for shipping crate and electrical connectors

Participated in design sessions for new wiring and structural concepts

Prepared site layout drawings for large solar farms in the desert Southwest

Mechanical Engineer, GE Nuclear, San Jose, CA (contract) 3/05 – 9/06

Designed new equipment for the power industry using Autodesk Inventor

Participated in design reviews of the product with the customer

Used product data management tool to track drawing release and changes

Interfaced with vendors to produce parts per customer design requirements

Coordinated structural and thermal analysis of designs and parts

Supervised draftsmen in the production of detail part drawings

Mechanical Engineer, End-Effectors, Inc, Santa Clara, CA (contract) 9/02 – 3/05

Designed robot end-effectors made of ceramic and aluminum made to tight

tolerances used to manipulate silicon wafers in the semiconductor industry

Designed next generation of probe cards capable of probing up to 10,000 points

Designed air cylinders to drive a mask gripper that is only 0.39 inches thick

Designed motorized equipment used to grind and lap ceramic end-effectors

Designed fixtures to facilitate soldering metal contacts to ceramic

Designed parts with AutoCAD, supervised assembly, and scheduled testing

Managed in-house computer network and AutoCAD drawing database

Coordinated relationships with company suppliers and vendors

Mechanical Engineer, Contrel Corporation, San Jose, CA 6/99 – 9/02

Designed and prototyped parts for new chip handling equipment

Designed and prototyped new test head manipulators for chip testers

Worked with vendors to produce parts to our specifications

Interacted with customers to determine product requirements

Designed products and created drawings using AutoCAD

Mechanical Engineer, Atmel Corporation, San Jose, CA 9/94 – 2/99

Designed and prototyped parts for chip handling equipment

Wrote preventative maintenance procedures and set schedules

Wrote training manuals and trained technicians to make repairs

Designed and fabricated tools to increase efficiency of operation

Set the CAD standards for the group and managed the drawing database

Trained new engineers in the use of AutoCAD to generate drawings


BS Mechanical Engineering, Tri-State University, Angola, IN (Co-Op 12 months)

Finite Element Analysis of Ceramic End-Effector for 450mm Semiconductor Wafer

As the semiconductor industry is moving from 300mm wafers to 450mm wafers, there are many challenges to be addressed. Since the wafers are larger and heavier, the bending of the end-effector will be more pronounced since stainless steel is a popular material to use. Historically ceramics have been used where high temperatures are involved in the processes. Now ceramics have become even more important for their stiffness. This end-effector was made of .025 thick ceramic sheets that are cut with a CO2 laser and bonded back together in a high temperature furnace. The top and bottom sheets are solid but the inner layers have passages for vacuum and other holes to lighten the assembly.

Jedec Tray Input for Semiconductor Chip Testing

Many modern semiconductors are stored and shipped in Jedec trays, which have a standard outside shape, but can contain different numbers of rows and columns to store smaller or larger chips. The operator places a stack of trays with chips to be tested into the machine, where they are supported by 4 pins on extended air cylinders. When the machine starts, the input elevator travels up and just touches the stack of trays. The air cylinders are retracted to release the trays and the elevator travels down exactly the thickness of a tray. The air cylinders are again extended to support all but the bottom tray, which is lowered to the surface of the machine. At this point 2 dowel pins push the tray under a safety shield and into the machine, where the chips will be picked up one at a time by pick and place robots. The dowel pins are powered by long air cylinders and guided by linear bearings. The safety shield can just be a sheet of Plexiglas to prevent the operator from reaching into the machine where the robots are working. After the tray is empty, the second elevator rises up and the dowel pins push the tray back and onto the top of the empty stack, which is stored under the surface of the machine. The elevators are powered by stepping motors which are controlled from a computer that takes inputs from sensors on the air cylinders and input stack.

Linear Actuator with Rack and Pinion Mechanism

Many companies need mechanisms to perform a specific task in a limited amount of space. The body of this rack and pinion actuator is just 3.62 in x 2.00 in and yet each end extends .75 in. The view on the left shows the actuator with the base and slide removed. The round racks sliding through plastic bushings easily support the motion. If rectangular racks had been used, ball bearings would have been needed on 3 sides of each rack for support and 2 more spur gears would have been needed to support the gear teeth side of the rack. The slide on the bottom prevents the end blocks from rotating and forces the jaws to travel in and out smoothly. The jaws can be modified for whatever the application might be. In this case I used a NEMA 17 stepping motor for driving the mechanism but other motors would certainly work.

Traffic Solution Camera Assembly

Many of the camera systems sold by JAI are used for reading license plate numbers which are then sent to another computer for analysis. This assembly has a camera which looks for a license plate and triggers the other camera to read the license plate number. There is an infrared LED assembly to illuminate the license plate at night. The plastic part that holds the LED’s is made by rapid prototyping (stereolithography) such that each of the LED’s is independently aimed at a different area of the target. This entire assembly was placed in a water-tight enclosure that I also designed.

Mask Gripper Mechanism

At End-Effectors I designed a robot end effector for picking up masks used in the photolithography process for making computer chips. The upper gripper is shown in the closed position. At the center of the assembly is a custom air cylinder with 3 pistons pointing to the right and three pointing to the left. The cylinder is just .312 inches thick and the whole assembly is just .390 inches thick. The air cylinder remains stationary while the upper and lower jaws of the gripper open and close to pick up and position the mask. The air lines to the air cylinder have been eliminated for simplicity. The lower gripper is shown in the open position. The pistons of the air cylinder have extended pushing the links and the jaws apart. One of the challenges that had to be addressed was that the jaws had to move together at the same speed so that the mask was picked up uniformly each time and to eliminate the creation of dust particles. To accomplish this, small plates about the size of business cards on the top and bottom of the air cylinder were pinned to the arms at the ends of the piston rods. The plates rotate as the pistons extend and force the arms on the left and right to track each other and pick up the mask uniformly.

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