Engineer Engineering
Resume:
MAYIER KAHN Ph.D., P.E.
NASTRAN / PATRAN, FEMAP, Abaqus Experience
Active Secret Clearance
Southlake, TX 76092
817-***-**** (cell) Email: ******.****@*********.***
Education:
Ph.D., Engineering, Kennedy-Western University, 2006
M.S., Mechanical Engineering – University of WA., 1998
B.S., Bachelor of Science in Mechanical Engineering – NYIT, 1992
MBA, Masters of Business Administration – City University, 2000
Six Sigma Black Belt Certification (DMAIC) – Chrysler – 1995
Fort Worth, TX FAA ACO, DER pending
Qualifications Summary:
Professional Engineering (PE) License, State of Texas. SECRET DOD Active Clearance. Twenty
eight (28) years of experience in the aviation industry specializing in the Fracture Mechanics /
Fatigue. Familiar with Part 23 & Part 25, Structural & dynamics loads, airframe structural / stress
analysis, structural modifications including supplemental Type Certificate STC. MRB action items and
full service remediation to all the rotary and fixed wing aircraft components . Application of finite element
MSC/NASTRAN, FEMAP, ABAQUS, LS-DYNA and CATIA V5, to DOD and NASA flight
hardware modeling and testing programming codes PCL, API.
EXPERIENCE:
07/2013 – 2/07/14 Trace aircraft Engines Lp, Midland TX. (Principal Engineer)
Worked on the (major repairs/modification STC’s). Responsibilities included sizing of the
new composite and metallic fuselage test planning and certification of the engines and
supporting structures and landing gear parts using FEMAP and CATIA v5. Performed
fuselage structural pull test with new engine, static, stiffness and fatigue life calculations
and recommended changes to the design team. Prepared stress documentation for FAA
Supplemental Type Certificate STC., Due to economic conditions the testing has been stopped
and there is no immediate need of my services.
6/2012 – 06/2013 Army Aviation Engineering Directorate (AED), Huntsville. (Principal
Engineer) Camber, Corpus Christi, TX
Direct responsible for the MRB, MEC-MEMO activity of repairs action items and full service
remediation to all the rotary wings aircraft. Fixed wing aircraft flutter analyses due heavy weapons
loading carried on wings per special missions carried out during war. The fatigue life evaluation and
damage tolerance substantiations for composite panels repairs, main rotor, and Blades dynamic
strength analysis / helicopter blades whirl tower balancing. Demonstration Blades components life
calculation detailed finite element modeling for impact analyses, Shock / vibration and other
environmental factors testing. Static structural analyses / crack growth analyses analysis. Reviewed
of structural discrepancies during aircraft major aircraft repairs MRB Stress for Liaison, static
analysis. Complex Excel spreadsheets to provide substantiations. Due to furlough the project has
been stopped and there is no immediate need of my services.
2/2010 – 01/2012 US Army Aviation Engineering Directorate (AED), Huntsville (2 years)
Stress Analyst
I was responsible for the MRB action items and full service remediation to all the rotary and fixed wing
aircraft components allow after repairs of aircraft parts with minor damage. Currently, many parts must be
Page 1 of 4
2
discarded due to incidental damage (scratches, gouges, and dents), because this damage may serve to initiate
a crack and ultimately a fatigue failure. In many parts, though, it is possible to remove the harmful effects of
this damage by blending it out over a larger area. Remediation analysis is used to support what repairs
should and should not be permitted. Because these parts are often fatigue-critical, testing should be used to
backup any recommendations obtained from the analysis. Remediation analysis involves a process, rather
than a straightforward analysis. In fatigue, a 5% difference in stress can be an order of magnitude difference
in life, so the analysis must be as accurate as possible. Rotor Systems Structural and Fatigue Analyst for CH-
47 heavy lift helicopter including rotor blade composite materials stress analysis testing. Tail rotor system
component stress analysis. Blade impact, bird strike, ballistic impact for helicopter components
2/2008 – 2/2010 US Army Aviation Engineering Directorate (AED), Huntsville (1 year).
Lead Stress Analyst
Under Contract Structural and Fatigue Analyst for helicopter modification programs for Army Aviation
Engineering Directorate (AED). MSC/PATRAN, modeling. Boeing Design Manual (BDM), Sikorsky, and
Bell Structural Analysis and Fatigue Manual application to military helicopter upgrade and modification
programs. Crashworthiness analysis of crew seats, landing gear, and helicopter airframes. Analysis of
advanced composite materials ballistics protection systems. Engine mount systems loads and stress analysis.
Analysis of composite materials weapons pylons. Structural flight test support for MH-60M Special Forces
Blackhawk helicopter mod program.
04/2007 – 02/2008 Raytheon / Beach Craft, Wichita, KS (2 years).
Senior Stress Engineer
Under contract to perform structural analysis on a special mission aircrafts program. Stress report
generation / review reports. Static / Fatigue analysis for FAA Supplemental Type Certificate STC
development & engineering authorizations, Created full aircraft substantiation reports for major structural
modifications. Stress Liaison for MRB-type activities (discrepancy resolutions) and, wing flutter analyses
due to extend range fuel tank and winglets installation on various Beach aircrafts.
05/06 – 04/07 Aircraft Stress Engineer Associated Air Center, Dallas, TX (11 Months).
Providing stress analysis and technical advisory support for all the wings aircraft. Airbus and Boeing VIP
aircraft projects interior arrangement grouping. Duties include FEM molding and sizing of various structural
attachments. Such as cut off new doors, VIP seats, galleys, Bulkheads, Toilets and supporting release of
Engineering Drawings. Coordinating with DER with respect to solving technical issues. Mentoring junior
analysts with familiarization to the analysis methods and helping them with providing documentation for
FAA reports. Produced reports for airworthiness Supplemental Type Certificate STC, reviewed by
Designated Engineering Representative DER an approved authority of the FAA. Airbus and Boeing products
including galleys and lavatories installations in accordance with FAR 25.
Lockheed Martin Corporation, Ft. Worth, TX (3 years and 3 months).
01/2003 – 04/2006 -
Senior Airframe Structural Engineer
Direct structural Engineer and Fatigue Analyst for F/22 structure and systems. FEMAP / PATRAN /
NASTRAN static, nonlinear, and dynamic loads and stress modeling. NASGRO fracture mechanics / fatigue
analysis. Preparation of Stress Analysis Summary Reports. Fuel and hydraulics systems stress and fatigue
analysis. F/22 Armament (AME) Systems Stress Analysis. F16 Block 60 armament stress. I responsible for
several composite skin panels and Joint analysis’s for the F/A 22 aircraft, The most recent projects were
Small Diameter Bomb, Night Air to Air refueling. Work was mainly associated with Weapons Bay, Main
Landing Gear Bay and Utility Bay. The analysis was extended to cover fuselage and fuel tank bays. Assessed
for all loading conditions including high air loads. Reviewed other engineers work. Modified the design of
various component and structure for improved structural integrity and performance while maintaining the
weight saving requirements. Performed nonlinear analysis, elastic-plastic, buckling and crippling of sections,
buckling of plates, etc. Improved LMCO program for high cycle fatigue assessment. All stress analysis was
performed using PATRAN/NASTRAN, CATIA, excel, Math CAD, Used MIL HDBK for material data and
F22 material Library.
Page 2 of 4
1/2002 – 12/2002 Delta Research Inc., Seattle, WA (2 years).
Senior Stress group Engineering Manager
Direct hired as a manager of engineering. Responsible for Finished a trade study project for the
Grumman/ATK’s James Webb Space Telescope. I created 6 cryo-mechanical FEM models to compare the
adhesive stress models with 5 different ISIM loading profiles. Results were filtered and processed in Excel to
identify joints requiring Step 2 analyses 61 joints were screened during the first iteration 213 joints were
covered in a second iteration of analyses that encompassed all remaining composites adhesive elements
strength. I performed structural design/analysis of a CMC body flap design for the X-37 and the next
generation Space Shuttle. Static and dynamic analyses using NASTRAN and FEMAP finite element
software. Systems Stress and Fatigue Analysis for Space Station and Shuttle subsystem components. Space
Shuttle and Space Station payloads integration, structural and fatigue analysis. Impact and penetration
mechanics analysis for meteoroid and orbital debris impact. Hand calculation stress analysis of spacecraft
system components.
Boeing MR&D Boeing Co., Everett, WA (1 year and 4 months).
8/2000 – 12/2001
Lead Stress Engineer
Responsible for structural integrity of new aircraft development programs and the focal point of engineering
discrepancies of 787 wing production in Japan. Responsibility also included managing several engineers and
providing engineers with tasks, scheduling priorities, mentoring, and cost containment. Analysis and review
of structural discrepancies during aircraft construction. MRB Stress for Liaison, static analysis. Complex
Excel spreadsheets to provide substantiations. CATIA. Metallic and composite structures.
Boeing Commercial Airplane Co., Everett, WA (5 years).
8/95 – 8/2000
Structural Engineer
Produced reports for airworthiness Supplemental Type Certificate STC, reviewed by Designated Engineering
Representative DER an approved authority of the FAA. Performed engineering stress analyses of the
Aircraft structure. Worked on wings, struts and empennage structure. Calculated load carrying capability of
individual members, and analyzed the critical load path. Performed fatigue and crack growth analysis
machined frames and intercostal attachments. Analyzed floor beams, galleys, Bulkheads and supporting the
release of Engineering Drawings. Preformed detail stress analysis of primary and secondary machined
brackets consolidating many sheet metal parts into fewer machined parts for the forward cabin. Impact / bird
strike analysis on forward body/cabin join area.
4/91 - 8/95 Chrysler Corporation, Detroit, MI (5 years).
Structural Engineer
Responsible for A-side Body and Door Assembly Line for Jeep Grand Cherokee. Responsible for process
design / analysis and prototype development of automotive stamping and tubular product. Design molds and
stamping dies for parts. Development of optimum production simulation and time study.
1/90 – 4/1991 McDonnell Douglas, Long Beach, CA (1 year and 9 months).
Structural Designer under a contract.
C-17: Horizontal stabilizer upper access door: Layout, conceptual / detail design of access panels and latches
using CATIA. Aircraft weapons systems design and structural analysis. Classical stress analysis of cast
ductile iron and steel bomb bodies and bomb racks weld joints. Explosives modeling and testing to support
U.S. Navy Insensitive Munitions Program.
6/85 to 9/86 E-Systems, Greenville, TX (1 year and 9 months).
Structural Designer under a contract.
C-130: Avionics test rack layout and detail design. Instrument panel and control console modification detail
design. Gulfstream GII: Layout of floor beam and seat track modification.
References: Upon Request
Page 3 of 4
4
Page 4 of 4
Contact this candidate