Mechanical Design
Resume:
** ***** *****, **** *******, NJ *****
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Thomas Nelson
Mechanical Designer
Experienced mechanical designer with considerable skills in design, innovation, and resource management.
Design
Communication equipment, paging products, rack mounted amplifiers, commercial loudspeakers, articulated
mounting systems, handheld electronics, and many related accessories on BOGEN.COM. Control and release of
production packages, as well as BOMs and other vital documentation.
• Injection Molding (ABS, PE, PC, EPS) and Rotational Molding
Focus on minimizing part count, material, complexity, and cost. Strong consideration
given to draft angles, parting lines, material flow, texturing, and model analysis.
Complex parts from simple tools.
• Sheet Metal Forming (SECC, CRS, SS, AL)
Small brackets and spring loaded electrical contacts to 40 inch wall mounted
enclosures. Maximum strength, minimum cost. Secondary operations including welds
and rivets, difficult bends and punches, are avoided whenever possible.
• Casting and Extruding (FE, AL, ZN, and alloys)
Extrusion used to produce heat sinks, front panels, and other high volume parts.
Casting for durable, visually appealing, detailed parts, including high strength
mechanisms.
• Rapid Prototyping
SLA, SLS, machining, and metal forming are utilized to test parts and assemblies.
Selected economically to test fit, function, or appearance.
• Finite Element Analysis
FEA employed for critical requirements or material reduction.
• Printed Circuit Board layout
Analog, digital, multilayer.
Management
• Managed full time, part time, temporary, and consultant based resources including mechanical engineers,
printed circuit board designers, industrial design engineers, and support staff.
• Worked with manufacturers to improve products and pricing.
• Developed a Product Design Procedure to assure consistent quality and efficiency.
• Reduced maintenance while improving BOM management and revision control.
Software
• SolidWorks - mechanical design, 3D modeling
• OrCad & Cadence Allegro - schematic capture, PCB design
• MS Access & Excel - data management
• GerbTool - manipulation of Gerber files
• AutoCad - legacy maintenance
• Cosmos - FEA analysis
Experience:
Senior Mechanical Designer
Bogen Communications, Ramsey NJ - 1999 – Present
• Design or specify every detail to meet the mechanical requirements of the products, including form, fit,
function, performance, and appearance. Attention given to Industrial Design and ergonomics.
• Provide all mechanical design services to the electrical engineers.
• Report to the VP of Engineering at a leading sound products and telecommunications manufacturer.
PCB Designer/ Draftsman 1982 – 1999
• Developed an electronic parts database for PCB design.
• Laid out high density through hole PCBs to be highly reliable.
• Double sided surface mount builds on 4 layer PCBs achieved the most serviceability.
• Wide variety of power supply, audio amp, DSP, microcontroller, telephone interface circuits, and many
others.
• Created assembly drawings, schematics, and PCB layouts. Performed tolerance analysis.
Mechanical Designer
Kayak Concepts LLC, Gardiner ME - 2008 (Consultant)
• Helped developed a modular system for the storage of kayaks.
• Stackable, load bearing structure with interlocking details provides safety and security.
• Parts are specially designed to be thermoformed or roto-molded, allowing economic alternatives.
• Twin sheet thermoforming also employed.
PCB Designer
KRYOS, INC., Kinnelon NJ - 1988 (Consultant)
• Worked with startup developers of a spread spectrum telecommunications system.
• Responsible for the layout of a digital correlator PCB using electrically programmable gate arrays (Xylinx).
• The design was accomplished using Tango PCB.
Education/Training
• Don Bosco Technical School - Graduated with honors from an advanced program emphasizing physics,
chemistry, and calculus.
• Technical Training - SolidWorks and Cadence software.
• Technical Training - EMI design considerations.
Patents
• Mounting Bracket - United States #7883065, issued 2/8/2011
Two piece adjustable bracket with snap together features.
• Speaker Mounting System - United States #7780135, issued 8/24/2010
Ceiling speaker mount that eliminates tile bridge and allows operation from front or back.
• Self-amplified Loudspeaker - United States #D531164, issued 10/31/2006
Horn speakers with unique appearance and band clamp.
• Arc Bracket - Provisional Application 61/881,688
Cam locked adjustable mechanism with arc motion.
Portfolio samples and references are available.
Thomas Nelson, Page2
29 Osage Drive, West Milford, NJ 07480
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