Donnell E. Crear

ac9qkk@r.postjobfree.com

Current Address:

** ***** ***** ****

Simpsonvile, SC 29681

513-***-****

OBJECTIVE

Mechanical Engineering position in the field of advanced manufacturing research & process development with a company that fosters creativity, forward thinking, and integrity.

EDUCATION

Ohio State University, Columbus, OH Graduated: August 2007

Masters of Science in Mechanical Engineering GPA: 3.79 (4.00 scale)

Ohio State University, Columbus, OH Graduated: December 2006

Bachelor of Science in Mechanical Engineering GPA: 3.79 (4.00 scale)

GRADUATE SCHOOL RESEARCH

Worked in Locomotion & Biomechanics Laboratory (November 2005 - August 2007)

Planar XY Table Development

oBuilt and developed a Planar XY Table that served as a prototype robot-assisted rehabilitator

oTable was later utilized to validate kinematic and dynamic models of the central nervous system (CNS)

Human Subject Testing

oInvestigated time-invariance in horizontal planar reaching motions

oFindings from study were used to develop a model for motor planning in the CNS

SKILLS

Creative clear thinker with a strong fundamental understanding of design of experiments (DOE)

Adept communicator capable of being an information liaison between technical and business leadership groups

Extremely experienced in use of additive manufacturing software (Magics, 3D Manage, 3D Lightyear)

Highly skilled in various additive manufacturing technologies (DMLM, SLA, FDM. Inkjet)

Proficient drafting and solid modeling skills (Unigraphics)

Well versed in custom machine design, fabrication, and acquisition for a wide range of industries

Proficient word processing, spreadsheet, & presentation skills (Microsoft Word, Excel, & PowerPoint)

Strong mechanical and machine design background

TRAINING

General Electric Edison Engineering Development Program (EEDP) graduate

Green Belt Certified

70E Electrical Training

Heartsaver CPR / First Aid Training

WORK EXPERIENCE

General Electric Power – Advanced Manufacturing Works (AMW), Greenville, SC

Senior Additive Manufacturing Engineer (Nov 2016 – Present)

Working in AMW Additive Manufacturing Team

Direct Metal Laser Melting (DMLM) continuous improvement

oSpearheaded the SLM280 gas flow upgrade kit development in joint venture with SLM Solutions GMBH that allows for 10-30% increased productivity over the existing SLM platform

oDeveloped a laser interweave algorithm that allows for multiple lasers to independently work on a single component while leaving a nearly indistinguishable interface seam

oDiscovered a manner to print holes in sidewalls of thin walled tubes capable of reducing the cost of each component set by $86.4K due to the elimination of the downstream EDM process

oProvided guidance on the roll out of fully released, compensated, center and outer fuel nozzle build files which represent $17.4M NPV in the final part manufacture

CoCr parameter development and material validation

oEstablished an improved 2.0 CoCr alloy laser parameter set capable of print time reductions of 29% compared to the 1.0 counterpart parameters

oValidated a CoCr alloy laser parameter set that was optimized to utilize the Hot Isostatic Pressing (HIP) cycle to heal as built component porosity by up to 1%, while allowing for 20% print time reduction

AMW additive team member mentorship

oActively mentored 4 early career team members to maximize their individual potential for the collective advancement of the team and betterment of their individual professional careers.

Augmented GE Powers IP landscape

oFiled 8 patents related to metal additive technology, powder handling, and additive part post processing

General Electric Power – Advanced Manufacturing Works (AMW), Greenville, SC

Lead Additive Manufacturing Engineer (Nov 2014 – Nov 2016)

Working in AMW Additive Manufacturing Team

Positioned GE Power as an industrial leader in the field of Direct Metal Laser Melting (DMLM)

oReduced average surface finish of parts made of CoCr alloy by 51% (14 µm to 6.9 µm)

oDeveloped an internal set of GE Power DMLM machine calibration procedures that yield laser alignment errors for multi-laser DMLM systems of less than 30 µm

oRan multiple cost out efforts related to DMLM production netting CAPEX savings of $2.0M+

Led AMW additive technology global alignment efforts following the acquisition of Alstom Power in Q4 2015

oDirected efforts to align the software and hardware on the entire fleet of SLM Solutions GMBH machines (21 total) shared between GE Power and the former Alstom Power

oStandardized the standard work and calibration procedures between the two companies’ original additive technology groups

Augmented GE Powers IP landscape

oFiled 11 patents related to metal additive technology, powder handling, and additive part post processing

General Electric Global Research Center (GRC), Niskayuna, NY & Van Buren Township, MI

Lead Process Engineer (May 2013 – Nov 2014)

Working in Electromagnetics & Superconductivity Laboratory

Facilitated the Efforts for the Design & Development of an Automated Gradient Coil Winding Machine

oCompleted a baseline of 3 similar industries in attempt to find appropriate approach & partner to build a fully automated custom machine

oWriting detailed machine specification for bid proposals on of a custom winding machine

Designed Key Process & Equipment Improvements for Current Gradient Coil Winding Process

oResponsible for 6 improvements and/or upgrades in current equipment and/or processes to facilitate higher accuracy & precision in the winding process

oWorking with Coil Builder modeling (in-house) software to model how real world fabrication errors translate into gradient performance degradation in an effort to develop a unique set of transfer functions for production tolerance understanding

General Electric Global Research Center (GRC), Van Buren Township, MI

Lead Program Engineer (October 2011 – May 2013)

Working at Advanced Manufacturing Technology Center (AMTC)

Developed Stereolithography (SLA) as a viable Next Gen Blade (NGB) alternative to multijet technology

oSuccessfully led efforts that resulted in the establishment of SLA as a viable printing alternative to multijet technology

oLed NGB team’s SLA development efforts from conceptual idea to onset of production

oUsing a 3D Systems Projet 6000, evaluated 3 unique SLA materials for NGB process compatibility in a four month period,

oDrove the SLA technology for NGB use from Manufacturing Readiness Level (MRL) 2 to MRL 5 in 16 weeks

oCompared to the existing multijet technology, reduced die raw material costs by 49% per die and die processing times by 16% using SLA

oReduced the surface roughness in the final core 83.5% using SLA over multijet technology

oIncreased the RP machine uptime to over 90% using SLA compared to 50% uptime of multijet

Managed the NGB Die Design & Experimentation Efforts

oAssisted in the creation and documentation of a robust set of die design rules for NGB dies produced with Visijet MX material

oEstablished die design rules for 2 SLA materials

oManaged and designed majority of die design & process interaction experiments

oActively worked with GE Aviation blade & heat transfer designers to educate them on product design limitations & specifics for design for manufacture

Process Engineer (July 2010 – October 2011)

Working at Advanced Manufacturing Technology Center (AMTC)

Transitioned Next Gen Blade (NGB) Process to AMTC

oAssumed Program Engineer role and coordinated the design of 7 custom pieces of equipment totaling $900K

oAccountable for the specification and purchase of 19 pieces of off-the-shelf equipment totaling $1.0MM

Designed and Built of Custom Injection Molding Systems

oSimultaneously managed the build of 2 custom injection molding systems from separate vendors

oInstituted weekly performance reviews to systematically solve the technical issues arising from each build

oFindings from each machine were used to create a more robust unit that mitigates future production risks

Assisted in AMTC Team Development Process

oRelocated to assist in green field startup of AMTC operation for GE GRC

oReviewed, screened, and/or interviewed 100+ candidates for 8 different positions

oConducted training sessions for new hires relating to T&L, sourcing, and compliance policies

oAided in the orientation process for new incoming MTC employees

General Electric Global Research Center (GRC), Xenia, OH & Niskayuna, NY

Edison Engineer (June 2008 – July 2009)

Worked in Process Systems Laboratory

Delivered NGB Pilot Production Line to General Electric Aviation (GEA)

oRelocated to Xenia, OH to completed 3.5 month GEA bridge assignment

oSuccessfully transitioned the NGB pilot production line from GRC to GEA

oDemonstrated acceptable pre-production yields of 52% through the 4 week acceptance run period

oProduced 233 acceptable cores over 8 week technology transition period

Trained GEA Employees in NGB Process

oTrained engineers in proper NGB line production procedures (10 different processes)

oProvided 120+ hours of hands-on training

oProvided 400+ hours of supervision following hands-on process training

Assisted in Electrochemical Discharge Machining (ECDM) Experimentation and Testing

oBecame established and reputable resource for ECDM experimentation

oDesigned thru-part flushing system for Ti64 HAZ studies

oInstalled prototype abrasive delivery system for improved molten chip flushing

General Electric Global Research Center (GRC), Niskayuna, NY

Edison Engineer (July 2007 – June 2008)

Worked in Energy & Propulsions Technology Laboratory

Designed and Tested Pulsed Detonation Engine (PDE) Derived Industrial Boiler Cleaner Unit

oBuilt and tested a GenII Powerwave+ prototype that demonstrated vast improvements over the GenI unit

oIncreased fuel flexibility from 1 to 3 fuels and increased the firing pressure by 243%

oDelivered operational GenII unit with operation/research documentation despite limited budget ($50K)

oWork on GenII Powerwave+ prototype resulted in patent application (US Patent App #: 200********)

Created New PDE Ignition System for Faster More Compact Detonations

oDesigned plasma ignition head capable of detonating fuel/air mixtures in standard PDEs

oDemonstrated industries first cold plasma ignited detonations above atmospheric pressure (3 atm)

oAchieved firing capabilities as high as 10 Hz

oDetermined a new dielectric insulator design resulting in a 75% reduction of consumed energy allowing for 30% voltage increases.

General Electric Global Research Center (GRC), Niskayuna, NY

Intern (June 2006 – September 2006)

Worked in Energy & Propulsions Technology Laboratory

Contributed to the closed loop system integration on Lockheed Martin funded project

Played an integral role in the projects selection of an adequate condenser & its implementation into the existing test rig

Created a bill of materials & instrumentation list for the additional hardware required

Assisted in running of combustion test rig and initial system shakedown

General Electric Aviation (GEA), Evendale, OH

Co-op (summer 2004 & summer 2005)

Worked in Combustion Test Laboratory (summer 2005)

oResponsible for TCA (Tunable Combustion Acoustics) configuration changes

oAided in pulse detonation testing

oConducted flow tests on combustor components & fuel nozzles

Worked in Industrial Aero-derivative Product Development Division (summer 2004)

oContributed in the collection and analysis of Gas Turbine and Power Plant reliability data

INTERESTS & HOBBIES

-Ardent semi-professional photographer & travel lover

-Enjoy bringing new BBQ cooking products to consumer marker for family owned catering business (Steamin’ Steve’s BBQ)

Contact this candidate