Engineer Power Plant
Resume:
Donnell E. Crear
*******.*****@*****.***
Current Address:
Simpsonvile, SC 29681
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