Mechanical Engineer Injection Molding

An Nguyen ***** Jetty Way, Hayward, CA *****

Phone (H) 510-***-****, (C) 510-***-****

Email **********@***.***

Objective:

Senior Mechanical/Manufacturing Engineer position utilizes problem-solving skills, process

engineering and material selection experience to design and manufacture products for medical devices,

energy industry, consumer products, semi-conductor. Design lifecare drug infusion pump, design RF

packaging gas smart meters, semiconductor main frame vacuum chamber, wafer handling mechanism, fiber

optic sensor for motion control system. Design electronic packaging for wireless RF. Design Lithium Ion

battery packaging and cabling. Specialize in design and manufacturing processes for plastics and rubbers

injection molding components. Design shock and vibration isolators.

Summary Of Qualifications:

Six years design experience of gas smart meters at system level. Design system architectures, gear mechanisms to connect

gas meters and smart meter modules.

Four years design experience semiconductor capital equipment, motion controls with linear actuator, servo or stepper

motor and positioning sensor or fiber optic sensor LED, laser sensor class II or I, ball bearing selection, gears.

Five years design experience of medical devices. Understand “Design Control Guidance for Medical Device

Manufacturers” (cGMP) FDA 21 CFR 820.30 and IEC 60601 -1 requirements.

Ten years experience in manufacturing of rubber and plastic products, gears, gaskets, tooling.

Abilities to carry projects from concept through high volume production.

Audit and approve plastic injection molding vendors.

Strong analytical and problem solving skills. Root cause analysis and provide solutions.

Design Sheet metal chassis for packaging power supply and c ontrollers.

Design many fixtures for production lines. The fixtures help speeding up assemblies.

Create design concepts and develop design spec’s. Hands -on experience with building prototypes.

Develop test procedure and build a prototype lancing device for diabetic meter.

Design electro-mechanical packaging for lifecare infusion pump.

Responsible for final design reviews, checking assembly-stacking tolerances, DFM, DFA before releasing.

Manage and set up plastic molding and assembly operations for high v olume production in China.

Lead cost reduction program by improving production processes from 38,000 to 52,000 parts per day and

as the same time reduced the production times from 24 hours to 12 hours per day.

Calculate and lay-out balance runner systems for multi-cavities molds, optimize mold cooling.

Estimate tooling costs, design molds, create drawings and instructions for vendors.

Managed successfully many projects.

Process engineering for rubbers and plastics injection molding, transfer and c ompression molding, extrusion.

Fourteen years design experiences and applications of shock and vibration controls.

Managed product development projects and designed a shock absorber for recoilless rivet gun that eliminates

wrist injury for aircraft rivet gun workers.

Mold medical grade liquid Silicone. Rubber compounding of SBR, NR, EPDM, Neoprene, Nitrile, Viton.

Technical support Sale, Quality Assurance Departments and directly resolved the problems with customers.

Developed test plans and fixtures for custom designs or use ASTM test methods. Performed the following tests on

materials and final products: UL94 horizontal and vertical burning test, UV resistant, Ozone resistant, heat aging, fluids

resistant, salt fog, tensile/elongation, shock and vibration.

Understand NAS 1316 rubber seal material testing procedures for aircraft hydraulic seals with Skydrol oils.

Experience with ASTM vol. 9.01 and 8.01 tests for rubbers and plastics.

Computer Skills: Solidworks 1998-2013, PDM Enterprise. Ansys FEA (Workbench 10), Solidworks simulation (FEA),

Microsoft Excel, MS. Word, Power Point, Matrix One data management., Arena, Agil.

Interpersonal skills: Negotiation with vendors, customer services.

Knowledge: ANSI Y14.5, hand-on with Micro-Vu (optical inspection machine), Vertical mill and lathe, DMTA, Rheometer, durometer,

Fortus 250mc (3D printer), tensile tester, injection and compression molding presses, and many ASTM tests vol. 9.01 and 9.02, 8.01.

Understand machine shop practices.

Professional Experience:

Channel MedSystems, Inc. San Francisco, CA. Design Consutant ( 4months contract, 11/3/ 2014 to 3/1/15).

Develop fixtures for assemblies micro components into catheter of Cryothermic Therapy device.

Silver Spring Networks, Inc. Redwood City, CA. Principal Mechanical Engineer For Smart Gas Meters,

July 2008 to Sep 2014.

Created product concepts and completed designing and launching 8 different commercial and residential smart gas

meters. There are approximately 600K installed in the fields.

Root cause analysis and provide solutions to injection molding vendor for resolving stress and dimension variations.

Designed RF packaging for natural gas smart meters.

Used ASTM tests to qualify materials, manage high volume plastic injection and rubber molding vendors.

Used standard procedure B109 for testing shock/vibration and fluid ingress test, UV resistant, salt fog tests for natural

gas meters that connected to smart meters.

Prepared test specimens for MET lab.to perform certifications.

Designed packaging for Lithium ion battery.

Supervised junior engineers, contract engineers.

Inspect and approve first articles. Resolve plastics and rubbers molding issue with vendors. Use Cpk index

to control process (variation of critical dimensions).

Coordinated with Sale, Purchasing, Manufacturing, Compliance Groups for designing and launching new products.

Cooperated with Sale team and came to customer's site to demonstrate how products functioned.

Cooperated with Tech Publish and Field Services Dept. to develop field installation instructions.

Managed plastics and rubbers injection and compression molding vendors.

Hospira Inc. Morgan Hill,CA. Member Of Technical Staff, Global R&D Department.

July 2004 to July 2008.

Completed designing and launching wireless (RF) capability into existing PCA3 Lifecare infusion pump.

Provided documents for Compliances Group to submit for 510K.

Develop concepts for new product, trouble shoot and resolve issues of existing products.

Technical lead and responsible for PCA 3 LifeCare drug infusion pump.

Write protocol and test procedures accordingly to IEC 60601 -1 requirements.

Perform finite element analysis to predict failure and optimized design.

Design plastic enclosure with EMI shield and lay out wireless PC board.

Manage and cooperate with plastic and rubber molding vendors for on time delivery and mold 's constructions.

Select and test elastomers for conductive gaskets, and pole clamp friction.

Study human factors on pole clamp that mounts the infusion pump on the moving pole.

Massie Research Laboratory, Inc. Contract Manufacturing Engineer. March-04 to June 2004.

Review casting part designs for manufacturability, manage and evaluate China vendors for quotation and future

manufacturing of plastic injection molding and die cast aluminium.

Complete an optical binocular packaging design for an eyes examination instrument.

The product was not passed the regulatory requirements and needed redesign. Manufacturing Engineer position was not

turned into a permanent position.

Seal Science, Inc. Irvine, CA. Senior Manufacturing Engineer, Aug. 2002 to Aug -2003.

Develop molding process for rubber, plastic parts and liquid silicone.

Develop or select materials for seal applications, medical devices.

Change the fundamental of existing manufacturing techniques. Results: Prevent under curing, more efficient, less

damaging to the molds, by mounting the molds to presses that prevented press operators pulling the mold out of hot press

during removing parts out the molds.

Root cause analysis of mold flow issues. Make correction to gates and runners of molds that caused flowing issues.

Review customer's designs for manufacturability, drawing and performed tooling quotes.

Inspect and approve first article parts.

Applied Materials, Inc. Senior Mechanical Engineer. 2000 - 2002.

Develop design specifications and test plans, DOE the effects of temperature on optic sensor.

Design mainframe PVD, ENDURA 2-300mm .

Design fibre optic sensor assembly, test laser sensor class I and II. Design wafer lift with servo or stepper motor and

Sanyo Denki or UMAC controller. Design fixture for camera system to measure and to survey wafer position after Local

Find sensors correction. Design lid lift mechanism with pneuma tic gas spring and compressed air actuator.

Therasense, Inc., Alameda, CA. Contract Design Consultant March -2001 to Nov-2001.

During economic down turn period, Applied Materials Inc. allowed employee temporarily take off W/O pay. I was a

volunteer to take off and worked for Therasense.

Design and test prototype diabetic lancing device. Research and review existing patents and avoid patents infringement.

AMS Industries, Inc., Consumer Products, San Leandro, California. Project Engineer: 8/199 7 – 9/2000.

Managed building a production factory in China to produce 52,000 dental floss packages per day.

Managed and technical supported vendors for productions of high volume plastics consumer products.

The products include contact lenses cleaner, battery power toothbrush, plastic gears, dental floss packaging. Set up

production operation, trained vendors to meet quality control MIL -STD 105.

Calculate and layout runner system for multi-cavities mold, calculate cooling capacity for injection mold s.

Searched and audited new vendors, resulted in better turn around tooling quotes, reduced tooling costs 20 -

25%.

Coordinated tooling design, delivery status of first articles and customer satisfaction.

Analysed and final reviewed plastic part designs for ease of manufacturing and low tooling maintenance.

Corrected tooling problem and resulted in scrap rate reduction from 30 -34% to the average of 0.7-1.5%.

Design plastic consumer products from concepts to final products.

Quoted entire product costs and delivery time frame, and provided the information to financial controller.

Research, audit and approve plastic injection, rubber molding vendors.

Mattson Technology Inc., Fremont California/Capital Equipment for Semiconductor Industry.

Reliability/Manufacturing Engineer: 2/1995 – 3/1997.

Introduced and designed plastic gears for wafer handling that cut cost, reduced noise, improved gear life.

Support Manufacturing Department in trouble-shooting part assemblies, set up life cycles and performance

tests, created assembly drawings and BOM. Designed new devices and redesigned parts/assembly to improve

performance and to reduce costs. Investigated (ECR) and provided solution (ECO).

Redesigned wafer handling device to minimize bearing and gear fri ction, reduced dynamic shock.

Result: Reduced particles and cut 50% bearing cost. Redesigned heater elements and heater block in process chamber to

extend heater service life and reduced heater element cost by 60%.

Resolved technical issues for 47 engineering change requests.

Burke Rubber Co., Custom Design and Moulding, Modesto California.

Product/Process Engineer: 1993 to 1995.

Project Management: Planed and coordinated inter-departments for development new products and manufacturing process es.

Improved old processes to cut manufacturing costs and reduced rejection rates.

Worked with cross-functional teams in manufacturing process development and improvement. Cut rejection rate by 15

to 20% and turned losing money products back to profita ble.

Debugged tooling problems for 35-40 molds, developed new processes and improved existing processes for more than hundred

custom molded products. It was resulted in shorter cycle times and improved part quality.

Resolved major rubber to metal bonding problems and helped preventing customers from taking the molds way.

Develop rubber compounds and modified existing compounds.

Rubber Development, Inc. San Jose California. (relocated to Iowa State)

Materials/Manufacturing Engineer: 1988-1993. Promoted to Research & Development Manager:

Manufacturer of custom designed tools, rubber rollers, rubber seals, valves, medical and electronic related parts, shock and

vibration dampers, mechanical goods, recreation products, and development of new rubber formul as.

Developed rubber compounds with efficient cure systems. Result: increase the efficiency of injection presses 10 -15%

(depend on part's size.)

Established relationship with vendors and researched for new vendors to cut 15 to 30% material costs.

Developed and implemented test procedures and established relationships between the test results and the performances of

custom made products. Utilized test results to perform calculations dynamic and static loads.

Started up a rubber-testing laboratory from scratch, hands-on experience with rubbers testing.

Results: Improved product quality, eliminated unqualified vendors. Directed all activities in the laboratory, responsible fo r

testing all vendor supplies and in house products meet Mil - specifications or ASTM requirements.

Cooperated with IBM's scientists in design disk drive motor shock mount, and cooperated with engineers of FMC

Company to analyse shock and noise reduction isolators.

Developed a low cost and reliable stepper motor damper to reduce set tling time and oscillation.

Studied the effects of oils on the life cycles of silicone rubber at high temperature.

Washington State University, Agronomy Research Center. Lab. Technician:1985 - 1987

Education: Washington State University, BS in Mechanical Engineering, December, 1987.

South Seattle Community College, A.S. Degree in Mechanical Engineering Technology, 1983.

Professional Developments:

Certificate for 10 units semester in Rubber Technology Intermediate Correspondence Course at Akron

University. Learned rubber compounding in two years with a thirty -five years experienced Chief Chemist.

Certificates of Photo resist and chemical vapor deposition equipment training.

Certificate for one semester of Applied Systems Engineering, Corne ll University.

Certificates of Solidworks Simulation Professional and Ansys Work Bench.

US Citizen

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