Design Engineer Mechanical

JOHN H. AUSTIN

*** ********* *** ********* ****, TX 78148

210-***-**** cell ******@*****.***

SUMMARY

(30) years responsibility in mechanical engineering mechanisms, package/product design, Aircraft sub-system/structure, plastics design, Tooling Design, DFMA, Six Sigma methodology Proficient in Cad: UG V6- NX8.0, SolidWorks, Parametric Sketcher- NX, Mathcad, GDT stack-up tolerance, TCE/NX(Product Data Manager), ASME Y 14.5M-1994, MIL-STD-100C.

KEY ACCOMLISHMENTS

Design efforts on JMCS project awarded Boeing Company $86 million in research

Retrofit design of helmet mount display units interface into fighter aircraft trainers

Flight Simulator architecture Design and Integration

Supported GE Hybrid Energy (SOFC) resulting in new government energy system.

Senior actuator design engineer for the Boeing 787, ARJ21/ Embraer 170 / 190 HSTA's

Fly-by-Wire actuation design, flight control designer engineer (Throttle Quadrants)

Senior mechanical design engineer in F-18 drop test Tooling Fixture design for naval aircraft deck landings and structural aircraft stress testing

EDUCATION

BSME, Concentration: Electro/Mechanical Design Technology

SOUTHERN ILLINOIS UNIVERSITY, Edwardsville, IL

PROFESSIONAL EXPERIENCE

GKN, Santa Ana CA

Mechanical Design Engineer, Tooling designer (NX 7.5 - 8.0) June 2015 - Mar 2016

Engineer support of 14 production punch press refurbishment/automation systems

Engineer/sizing, load calculation for new drive systems and mechanical support equip

Built specification of requirements of drive systems to support purchase orders for semi automation and full automation

Closely worked with automation specialist vendors in system architecture development and value stream mapping for Ribbon Press design and Panel Fab design

Replaced mechanical speed reduction drive devices and clutch drive system for a programmable controller for each punch press

Redesigned mechanical punch press supporting devices in production manufacturing to meet lower scrap rate requirements controlling tolerance at each press tooling station

Evaluated current punch press Roller Feed system in recommendation of servo feed vs current clutch ratchet drive with interfaced rack and pinion gear design

Redesigned form tooling dies for titanium ribbon design to support variable notch tooling

Developed evaluation matrix of current camshaft ram design vs roll forming tooling in cost analysis

Developed evaluation matrix of punch press ribbon manufacturing and created refurbish vs automation cost analysis

Production manufacturing tooling support of Punch Press and Panel Fab machines to evaluate failure analysis reports and corrective actions to increase productivity and reduce scrap rate

Incorporation of Manufacturing ECN

Developed Master Cad models in presentation of redesigned Ribbon Press and Panel Fab machinery to Program Engineering

Design support of Boeing form tooling and welding/form fixture/set-up stands

Redesigned Boeing form/assembly tooling to meet weldment assembly requirements

Introduced Additive Manufacturing to Program Engineering in support of form tooling of Ti-wall vacuum forming techniques

Northrop Grumman, Annapolis MD

Mechanical Design Engineer, Tooling design support ( NX 8.0 ) April 2015 - June 2015

Engineering design upgrade of maintenance stands for underwater armament

Prototype design development support of 3D printed Additive Manufactured heat sinks

SLA models developed for validation of assembly and tooling consideration armament

Engineering design checker supporting manufacturing and product development documentation for internal engineering processes

Incorporation of Engineering Change Orders

Design documentation of redesigned assembly maintenance stands for armament military depot

Supported non secret clearance activities in product pprogram

Textron Systems, Hunt Valley MD

Mechanical Design Engineer, System design ( NX 7.5/Solid Works ) Oct 2014 - March 2015

Design support of Unmanned Marine Influence Sweep System

Design support of drive systems and avionic signaling systems / packaging

Design support of power pack systems start & run avionics / packaging

Design support of actuated linear drive system for antenna mask

Design of signaling avionic packaging in system design

Designed per DOD-2134, DOD-160, MIL-2003

Panasonic, Peachtree City Ga July 2014- Oct 2014

Mechanical Design Engineer, Product design ( NX 8.0 )

Design support of video/audio display units for automobile aftermarket industry

Designed plastic housings, bezel cover plates for touch panel technology

Designed sheet metal / bezel housing structure to meet vibrat

ion requirements

Design support of PCB boards to meet electrical component space requirements

Space X, Hawthorne Ca January 2014- May 2014

Tooling Design Engineer, GSE ( Launch vehicle ) ( NX 8.0 )

Forward cradle fixture design to support Falcon Heavy and Pad-39a design

Designed forward cradles, sling and TE Strong back layout structure ( Launch V )

Designed Sling ( Machining ) interface with Flight Vehicle to measure load ( Heavy ) after pressurization of LOx Dome, Common, Fuel and Interstage during flight vehicle loading and pre-launch

Supported Hydraulic load measuring design, cylinder mounting, barrel pin design

Eclipse Aerospace, Albuquerque NM Oct. 2012- Dec.2013

Structural Design Engineer/ Interiors ( Solidworks secondary Cadd tool )

Structural Interface / Interior design engineer of cockpit /cabin. ( Payload )

Interior composite kydex / foam core design of upper and lower cabin wall shell.

Mechanism design / Component design of interior Isolation design/ cabin interiors

Mechanism design / Seating latch at structural seat track interface

Redesigned Interface brackets to bulkheads and interior stringers. Create supplier definition cabin/cockpit interiors to meet customer / pilot requirement / tooling.

Incorporation of Engineering Change Orders

Designed cam latching mechanism for redesigned passenger tray table/cup holder.

Designed 3D printed interior clips to support structural load path to outer bulkhead.

Plastic component design for weight savings, supporting materials in design, Ultem 2300/9085, Zytel St801, Nylon 6/6 glass filled.

Composite ply design of interior cabin and cockpit, misc components

NX 7.5 used in master model definition of design advanced release submittals

TeamCenter engineering 8.3 used for PDM

Bell Helicopter/Textron, Tarrant Co Tx Sept. 2011- August 2012

Structural Design Engineer

Structural Process design/manufacturing engineer for Bell Helicopter/Textron H-1 ZBN Mod. Manage supplier variance and issue reports in Enovia. Variance incorporation processing in Enovia / MRB process and procedural architecture.

Variance Incorporation limited effectivities

Enovia 6 used in Process routes and Procedural ECO incorporation

SIARS indentifying validity of request for change and Approval of descrepency

Nx 6 and Catia 5 used in master model definition design correction and submittal

GE Energy, Houston Tx June 2011- Sept. 2011

Cadd Designer NX 7.5

Design configuration consultant of mechanical and plumbing systems architecture.

Sheet metal layout/design of large package assemblies for energy producing reusable jet engines

Design support of piping/plumbing gas mixtures for high voltage output systems

Retro-fit design of Turbine Jet Engines to voltage output architecture

Turbine blade retro-fit design rebuild

Manufacturer liaison in rebuild of Jet Turbine Engine

DRS Technologies, Milwaukee WI Feb 2011- May 2011

NX 6 Cad Training- 40 hrs

NX 7.5, 160 hrs

(TCE) Team Center engineering architecture training- 80hrs

Design configuration cadd modeling and teamcenter PDM configuration updates support.

Incorporation of Engineering Change Orders ECN/ECO

Honeywell, Torrance Ca. ( Contract ) Sept 2010 - Jan. 2011

ADVANCED DESIGN SPECIALIST

Project Liaison in support of product Nacelle and Actuation Test Procedures

Jackscrew actuation testing/product design in control of fuel flow E/M actuated valves

Project Engineer/Design management of: test requirement action Item reports, redesign stress reports, tolerance study 3 concurrent designs reports

Performed Thermal analysis tolerance stacks of -65f to 185f bushing/tube sub-systems after negative life cycle test reports of 3 concurrent designs

Data collection and fracture/failure analysis studies

Project design lead in Project Drawing Document and Packaging support

Bearing/Bushing tolerance stacks and fit, form, function system design

Completed ESD Certification, system testing, redesign validation

Pro-e, Unigraphics Nx5 and PDM design support

Maxim Integrated Products, Sunnyvale Ca. - Autocad/Solid Works June 2009 - Sept 2010

PRODUCT MAINT. ENGINEER ( Six Sigma process data collection )

Qualifying reactor tools daily to support quality of micro-chip technology

Collect data and input chart graphs to track reactor tools maintenance trends

SPC reactor tool maintenance control and product support of CVD reactors

Certification received 12/09 on reactors 20rct thru 8rct, 5hdp and 6hdp

Certification received 12/09 on Particle Surfscan, UV1050, UV1250 and UV1280

Certification received 12/09 on FTIR Bio-Rad and Stress Measure

Redesign support of thermal pre-heat reactor modules, Six-sigma process used in failure analysis

Alliant Defense Systems, ATK Mesa, Az - Contract July 2008 - March 2009

MECHANICAL DESIGN ENGINEER (NX4 - NX5) Team Center

Conceptual design of system mods for medium and large caliber chain guns

Legacy data modifications to support large caliber experimental chain gun

Incorporation of Engineering Change Orders ECO/ECN

Design support and experimental release of 50 caliber chain gun

Designed receiver and feeder mods for 50 caliber experimental chain gun

Designed customer support tooling to meet mechanism maintenance requirements

Supported engineering change proposals contract of MK 19 military gun

Design support of linear velocity centrifuge actuation igniter

Customer requested pressure valves design to dispurse carbon gas (Munition Fire)

Mechanical design support of DC motor electro-magnetic feedback to control misfires in SEAR ( Dwell )position, feed control design and case ejection of new design munitions

Jet Propulsion Laboratories, Pasadena, CA - Contract Nov. 2006 - July 2008

MECHANICAL DESIGN ENGINEER (UGII NX2 - NX4) Team Center

Supported mechanical systems design for the MARS land rover project, primary mechanical design for decent stage rocket powered tool and rover deck interface

Designed mechanical and structural descent vehicle systems, flight hardware and test equipment for proof of design

Mechanical designer for primary structure in support of bridle and umbilical device of the descent stage vehicle

Liaison actuation design support cost reduction in housings and manufacturing ball screw techniques and controller support architecture

Redesign decent stage E/M actuation torque tube linkages to support load variations during Mars Rover landing

Designed clevis mount bearing housings and clevis mount structure

Rockwell Collins, Irvine, CA - Contract to Permanent July 2005 - Nov 2006

SENIOR DESIGN ENGINEER (UGII NX2) HSTA's

Designed ball screw actuation system concepts to translate linear motion

Designed for failure analysis per customer and FAA requirements for small, mid range commuter aircraft

Actuator design under master model concept, controlled support part design & analysis

Engineered resolver housings, dog stops, end fitting clevis mounts, reset rods, torque tubes, primary load path bearing housings

Designed helical/worm, bull gear interface with resolver gear set architecture

Designed close tolerance paired bearing housings, axis bore alignment bearing and end

fitting housing design

Designed lvdt/rvdt/resolver mechanical architecture to support position, angular/linear sensing and brushless DC drive timing

Designed mechanical architecture for hall effect sensor to read current density changes in DC brushless motors to support controller design

Designed ball screw embedded miniature lvdt mechanical architecture for linear displacement sensing

Designed potentiometer mechanical architecture to validate controller design

Designed casting that supported lube housing design, actuator housing package

Completed hand calculation for sizing gear design and material selection, thermal cond.

Design for manufacturing techniques to reduce scrap and material cost

Designed environmental test fixture tool for Thermal analysis and Load requirements

Tracked cost and budgeting of electro-mechanical components for CDR and company progress reports. Tracked man loading for design support to meet schedule requirements.

Designed components for commercial cockpit trainer interface of fly-by-wire design

GE Energy, Torrance Operations Los Angeles, CA - Permanent Jan 2005 - July 2005

SENIOR SYSTEM DESIGN ENGINEER (UGII NX) I-MAN

System Packaging designer of research (SOFC) Solid oxide fuel cell project. DOE new energy source.

Designed bell housing pressure vessel of temperatures in excess of 800c to 975c

Designed Jig and fixtures of thermal 20 piece flow stack design

Designed E/M thermal inlet flow valves for pre-heated gasses incorporating flow stack mixtures, linkage design, interface ballnut design

Packaged design proposal for government funding and approval of process

Prepared cost analysis in system build for government contract package

Responsible for complete drawing package and of material/components

Tracked component life cycle during system testing and degradation of components

Generated internal component design specifications during life cycle testing upgrades

Logged 400 hours in system test analysis and system power output m/graphs

Design for Six Sigma training, system design analysis.

Moog Inc., Chatsworth Operations, Los Angeles Ca - CONTRACT Sept 2004 - Jan 2005

SENIOR DESIGN ENGINEER (UGII, 18) I-MAN

Designed support DC brushless E/M actuators for Boeing/Goodrich NASA project.

Retrofitted legacy data braking systems for 4 project actuators

Designed solenoid braking system for actuators to translating drag thru pinion gear shaft to support hall effect sensing design and controller architecture

Designed components used in tolerance studies, and Master Model assembly

Responsible for drawing package for braking system & bill of materials for cost to build

Boeing Co. Training Systems, St. Louis, MO - May 2002 - Sept 2004

SENIOR DESIGN ENGINEER (UGII, V18)

Mechanical design of F-16 & F-18 trainer cockpits retrofits into Navy operations systems, Retrofitted Visual Display Unit into fighter aircraft cockpits

Incorporation of Engineering Change Orders ECO/ECN

Designed support AH-64 Apache helicopter structural/mechanical linkage, trainer design

Designed HUD package displays units for cockpit trainers, F18, F16, Apache helicopter

Designed HVAC unit and vent tracks for retrofit into cockpit, sterio lithography design

Designed helmet (HMU) tactical optical display units, retrofit for Lens and camera mount packaging inside the helmet unit to correct optical distortion on to helmet glare shield.

Lead mechanical design engineer, F-18 drop test fixture for the navy

Designed (GSE) equipment/tooling for F-18 retrofits, and armament munitions loading

Innoventor Engineering - Permanent April 2000- May 2002

MECHANICAL DESIGNER (UGII, V18) CATIA, V4 Bell Helicopter, Fort Worth TX

Structural redesign of "UH-1Y & Z interior configuration Power plant firewall Rotocraft.

Nacelle gas valve and linkage design support of fuel and air mixture, drive system

Supported outlet exhaust Nacelle linkage design

Titanium/aluminum firewall apron design of forward, center primary structure.

Designed apron skeletal structure and documented interface design with interior structure.

Tool/fixture design support for firewall sub-assembly apron locator mandrel pins

Design support of riveting and drill press set-up tool jig machinery

Primary Load path structure design in Power Plant quadrants interface Main deck.

Sino Swearingen, San Antonio, TX - Contract May 1998- April 2000

MECHANICAL DESIGNER (UGII, 16 &18)

Redesigned flight control Aileron trim sector to new design specification

Redesign SJ30 mechanical system interface with support structure per FAA requirements for certification of aircraft, far23 design requirements

Designed actuator end fittings for mounting wing flap design

Corrected design flaws, and redesign for loads in fly-by-wire system

Redesigned of set-up fixture for fuselage re-modifications and new design twin engine housings, jet engine build-up

Liaison Powerplant build/design, Solid modeling, sheet metal design

Redesigned throttle pulley's to support new cable specs, and new engine throttle control gains

Designed family of detail parts to support new engine throttle control.

Designed wing box assemblies, Ailerons and structural Spars

MCDONNEL DOUGLAS, BOEING (MDTS), St. Louis, MO Oct. 1988 - April 1998

SYSTEMS DESIGNER A (UG11, V11-V13) Contract / Permanent / Contract

Project Engineers concepts Implementation and modifications.

Structural support design of welded components forward and aft of cockpit, cradle

Simulator Integration design of F16/F-18 Cockpit Trainer into VIDS (Visual Integrated Display System Trainer) Master model Assembly.

Simulator Integration design support of AH-64 Apache helicopter avionics upgrade

Engineering Change Order Incorporation ECO/ECR

Hud display interface design with cockpit and VIDS cradle design

HVAC ductile sterio-lithography design for cockpit structure, human factor design

Depot liaison fracture/failure support of 1500 hr flight tests of F-18 A/B fighter aircraft

Designed reconnaissance pallet for F-18A

Designed weldment lift fixture for reconnaissance pallet for F-18A

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