Mechanical Engineer Engineering
Resume:
ALFRED M. CHUNG
E-mail: ***********@*****.***
SUMMARY
An experienced, innovative Mechanical Engineer with solid engineering knowledge and skills in the mechanical design and product development of complex electromechanical/optomechanical capital equipment, instrument used in medical/life sciences, laser/photonics and aerospace industries.
Knowledge of PDP III design control and product development process (Concept to Commercial Launch), DFMS (Design for Manufacturing & Serviceability), Design Transfer, Oversea Vendor Management, ISO requirements, GMP guidelines, Total Quality Systems.
Extensive engineering design experiences and knowledge of 2-D and 3-D solid modeling, thermal/stress FEA using Pro/E (Wildfire 2.0, 2001, 2000i), Pro/Part, Drawing, Assembly, and Sheetmetal, Surfacing, Process, Diagram, and Promechanica, Intralink 3.3, PDM, Siemens Team Center PLM, Agile, SolidWorks, SDRC IDEAS (Master Series 5.0), CADAM, and CATIA application software. GDT ANSY Y14.5M (Geometric Dimensioning and Tolerancing) certification.
Knowledge of Steady-State, and Finite Element heat transfer and stress analysis tools such as IECS (Integrated Environmental Control System), TSS (Thermal Synthesizer Software), IDEAS TMG (Thermal Mesh Generation), and ANSYS. Solid knowledge of FEA (Convection, Conduction, & Radiation) heat transfer analysis of both active and passive aircraft/spacecraft thermal control systems and components.
Advanced knowledge of machine shop practices, fabrication techniques of metal, high strength and corrosion/heat-resistant alloys, bimetal, SMA, elastomer, high performance thermoset and thermoform plastics. Material processing: machining, micromachining/laser cutting & welding, rapid-prototype plastic (FDM and Stereolithography), stamping, etching, bead blasting, plating (copper, chrome, nickel, silver, tungsten carbide, zinc), lapping, electropolishing/passivation, anodize, alodine, vapor polish, stress relief, plasma spray, Wire EDM, extrusion, sand and investment casting, epoxy and UV curing, ultrasonic welding and cleaning.
Knowledge of writing/releasing engineering change documents such as ECO, repair, test, maintenance procedures, and pilot line documents.
Experience in engineering project management, planning, and reliability improvement projects.
Ability to write concise engineering specifications, PDR, and CDR reports, and conduct engineering design review meetings.
EXPERIENCES
COHERENT, Santa Clara, CA 2015-2016
Opto-Mechanical Design Engineer, Staff
Lead team of junior engineers, technicians, manufacturing personnels to design, develop, implement, and release of the company’s first generation high current/power, multi-KW (4KW, 1080 nm Near Infrared laser) opto-mechanical Fiber Laser System, and the Diode Pump Solid State (DPSS, 975 nm Near Infrared Laser) Laser System used for industrial/material processing application. Perform detailed opto-mechanical and electrical system design and selection of the precision optomechanical components: rack and chassis (19” & 23” Racks, 1- 4U), high current contacts/connectors, wire and cable harness, fiber assemblies (Oscillators, splice, delivery and gain fibers etc), laser head, optical pump engine, combiner, modulator, Fiber Tray, Fiber to Fiber Optical Switch, stability support, kinematic mount and alignment mechanisms, vacuum, and thermal controls/cooling electromechanical subsystems.
Design and fabricate test stations, fixtures, tooling for production use.
Research/develop material specifications, and manufacturing process such as high current connector crimping tecniques, soldering, plating, epoxy, ceramic base and bus bar material, and CTE-match material used in manufacturing both the Diode Pump Solid State and the Fiber Laser systems.
Develop thermal solutions (Water and Air Cool) to cool critical laser components: laser head, beam dump, splice, oscillators, KW optical pump engine, modulator PCB, fibers. Perform FEA structural and thermal analysis of the 4KW Fiber Laser System. Design and develop an innovative kinematic mount mechanisms to support the pump engine subsystem.
Manage and train manufacturing technicians, mechanics, buyers, planners and external vendors, contractors to build products efficiently, safely, and meet aggressive delivery schedule.
Transfer R & D designs to Manufacturing. Create and release engineering and manufacturing documents, BOMs, ECO, and ECO Deviation thru Agile and EPDM under company’s internal Quality Systems.
ABBOTT DIAGNOSTICS, Santa Clara, CA 2011 - 2014
Senior Product Development Engineer
Lead team of Electrical, Software, Mechanical, System, V&V Engineers to design and develop the company’s next generation robotic automated hematology instrument which includes the optics/laser, vision system, robotics X-Y-Z-THETA Stages, diluent reconstitution, reagent handling, water purification, chemical delivery and mixing, pneumatic, waste, incubation, and motion controls subsystems. Research, specify, design, procure, build, test and characterization of the high-precision fluid/blood handling components such as metering pump, injection pump, microfluidics features, inert valve and fittings, manifold, ultra-pure water purification components, filter/degasser/debubbler, robotic arm, motion control/DC and stepper motor, fan, heater, sensors and electronic controls.
Design, analyze, build, and troubleshoot these prototype mechanical subsystems and components using SolidWorks CAD & Siemens Teamcenter PLM software, Labview, Python flowscripts, Mathlab, JMP and real-time data acquisition systems. Design sheetmetal, machine, and plastic injection mold parts such as enclosure, optical housing, wet/capacitance/mechanical electrodes/sensors, fluid-handling and motion control components/systems – needle cap piercing and aspiration, as well as motor stages and small mechanisms.
Design, develop, and test fluidic processes such as heating, cooling, resuspension, filtration, mixing (radial and axial), aspiration, dispensing, liquid level sensing, clot and bubble detection.
Write and execute design experiments and test protocols with Python CLI flowscript/Labview to characterize, verify, and validate the new designs. Analyze cell data and optimize system and component performance: accuracy, precision, throughput, count and mixing CV, Optical vs Impedance MCV (Mean Cell Volume) and osmolality guardbanding tolerance study.
Coordinate design activities with EE/SW/Manufacturing, consultants, vendors, and suppliers to vertically integrate these systems onto the analyzer instrument. Transfer designs from R & D to manufacturing.
Prepare and present technical reports and presentations to peers and senior management on a regular basis.
STELLARTECH RESEARCH CORPORATION, Sunnyvale, CA 2007 - 2011
Senior Mechanical Engineer
Design and develop an innovative, next-generation RF balloon-catheter assembly and a low-cost, fully-automate balloon (inflate/deflate/vent) pneumatic system used for the Barrx’s HaloFlex 360 esophageal cancer treatment application. Manage engineering design, development, and verification testing of the Halox Flex 360 generator electromechanical system/components, RF cathether, and its accessory components such as bezel, footswitch, cable assemblies, pneumatics, and RF generator chassis systems.
Mechanical engineering design, development, and test of a complex surgical handpiece electro-mechanical system consisted of fiber optic, mechanism, a high-frequency (6 MHZ) monopolar RF PCB, pneumatic and fluidics, and a patient-contact electrode components used for non-invasive, collagen tissue ablation, aesthetic, and gynecological applications.
Mechanical design and development of a remote steam vapor generation and control system, and a disposable, RF-based steam-generation tip catheter system designed to treat peripheral vascular and lung diseases. Define and optimize system architecture and component requirements to meet design and safety requirements.
Experimental design and develop a high-voltage, RF energy, guided-wire catheter-electrode assembly comprised of tungsten, SMA (Shaped Memory Alloy) nitinol wires/guide tubes, and advanced dielectric and ceramic material for spine surgical applications.
Experimental design a bipolar, RF-based, disposable electrode assembly using partially-insulated, ultra-fine acupuncture needles for hypofraction cosmetic surgery. Manage system integration of the RF generator, coolant and vacuum modules, handpiece, and a disposable, ultra-fine needle array assembly.
Mechanical design and optimization of the electromechanical motor, gear reduction system, miniature steering mechanism, fluidics, and a flexible, high torque, transmission/aspiration shaft assembly used on a surgical handpiece device designed for human bone marrow harvesting application (Hospira – MarrowMiner®). Design and optimize laser-cut pattern hypotube, single and multi-filars encapsulated coil, aspiration tip. Develop and validate tooling fixtures, laser weld and silver solder joints, polymer liner coating, cleaning and sterilization process.
Perform market research of advanced polymers, thermoset and thermoplastics, elastomers, and biomedical compatible materials which are commonly used in the development of these medical devices. Manage and select vendors and development partners to share development risks and to provide high quality material/components, services to meet specific product design specifications, ETO/Gamma sterilization process, GMP, FDA and ISO requirements.
Design and document machine, sheetmetal, injection mold plastic parts, assembly, drawings, and test fixtures using SolidWorks 2010. Create, review, approve, and release accurate documents of the design concepts, component specifications, drawings, assembly procedures, robust manufacturing process, test methods, acceptance criteria, verification and validation test protocols, Design/Process/User FMEA in compliance with company’s Design Control procedures and Total Quality System.
Interface closely with software, electrical, quality, manufacturing personnel thru out the design and development phases of the products.
HOSPIRA - ABBOTT LAB - Critical Care Division, Morgan Hill, CA 2007
Senior System Engineer (Contractor)
Mechanical development of the pump mechanism assembly and components (SolidWorks 2006) for the next generation, critical-care, 4-channels, high-flow (1 - 1000 ml/hr, 95% volume/rate delivery accuracy) infusion pump assembly. Developed and optimized piston valve, blocker cam and cam follower, stepper motor, 8-bit absolute magnetic rotary encoder, solenoid, and electro-mechanism to meet design and reliability requirements.
Designed calibration and test fixtures to evaluate prototype and pilot builds of the IV pump electromechanical system and components.
Performed engineering stack tolerance and GDT analysis of the pump mechanism, linkage, and controls during the initial prototype build.
Performed FMEA and risk mitigations on the disposal, drug administration cassette. Analyzed maximum drug delivery VTBI (Volume To Be Infused) at worst case conditions due to mechanical failures of the cassette assembly. Establish risk management plans, wrote report, and recommended corrective actions to prevent failure occurrence.
Executed design experiments and performed statistical analyses to determine drug volume and rate accuracy at various and worst case operating conditions. Performed engineering development testing and troubleshooting on the Symbiq infusion pump system to resolve issues such as occlusion and air bubble detection to further improve patient safety and product performance.
TYCO HEALTHCARE – Respiratory Division, Pleasanton, CA 2003-2006
Senior Mechanical Engineer - Research and Development
Applied FDA-approved, PDP III (Concept, Feasibility, Development, Qualification, and Launch) Design and Control principles and Total Quality Systems toward the engineering research, design, development, and evaluation of a high-dose, H850 Portable Liquid Oxygen Unit to treat COPD patients (Chronic Obstructive Pulmonary Disease); and an acute care mechanical ventilator.
Analyzed/translated market studies and customer requirements into PRD (Product Requirement Document). Designed system architecture, prototypes, and performed feasibility studies and testing of these prototypes.
Performed detailed engineering design of the Emerald BDU (Breath Delivery Unit – Air/Oxygen Mixture System), and the Exhalation pneumatic systems and their components. Utilized Pro/E Wildfire to perform detailed engineering design layouts of the machine, plastic injection mold, sheetmetal parts and assemblies. Applied engineering design calculation, GDT, and Six Sigma Design Principles in the design and development of these critical-care medical devices/systems.
Created engineering drawings, BOM, and ECO through pilot and manufacturing release (Agile System) of the mechanical components and subsystems.
Set up LabView and ARTS (Active Response Test System) Data Acquisition Systems to analyze both steady-state and transient response of these medical instruments. Resolved thermal and EMI noise issues on air and oxygen flow sensors. Traced product output requirements to meet design specifications.
Wrote and executed test protocols to meet stringent medical product design verification and validation requirements. Conducted thermal, humidity, shock, vibration, drop, EMI, and Full Life Cycle tests of the new/derivative products to verify product reliability and output requirements. Performed FMECA and CAPA as required to comply with FDA, ISO, requirements.
Prepared and documented technical design review reports, Meeting Minutes, and conducted technical design reviews and presentations to upper management and peers.
Identified and interfaced with vendors to obtain and explored new engineering products (air/oxygen flow sensor, Zirconia oxygen sensor, and NEMS), materials, and processes, and test equipment in the current competitive market.
Worked closely with electrical, controls, and manufacturing engineers, technicians and other support personnel to assist in debugging, optimizing, and integration of these ventilator and cryogenics mechanical systems/components.
Wrote invention disclosure and file patent application on new invention with corporate legal and Patent Attorney. Received one patent invention award - An Variable Diameter Tracheal Tube.
MATTSON TECHNOLOGY, Fremont, CA 2000-2002
Senior Mechanical Design Engineer
Utilized Pro-E ( 2000i, 2001, Intralink 3.0) to conduct design and manufacture the vacuum robot wafer handling system, and the Type II Ion/plasma source generation hardware (coil, RF, bias match, Faraday Shield, quartz vessels, gas distribution shower head), universal gas box, and gas distribution systems used on the Highlands 300mm, high productivity photoresist/strip module. Conducted strip and lite-etch process experiments to validate new hardware designs. Transferred new designs to manufacturing.
Utilized Pro-E ( 2000i, 2001, Intralink 3.0) to conduct design and manufacture of the Aspen 3 Strip process modules, subframe, chamber, top plate, heater block, wafer pedestal, wafer lift pin mechanisms, Faraday shield, quartz components, cage, ultra high vacuum components, Osaka and Pfeiffer turbomolecular pumps and controllers, RF generators, gas box, gas weldments and pipings, electronic enclosure consisting of EMI/RFI shielding, and sheetmetal components.
Generated layouts, details, and assemblies of the gas box, gas weldments, pipings, and vacuum lines used on the Strip Module. Work with UCT (Ultra Clean Technology) on integration of the universal gas box.
Wrote technical proposals, specifications, and design review reports. Conducted engineering design review meetings to program management and customer personnel.
Interfaced closely with electronics, software, certification, vendors and suppliers, field service, marketing, purchasing, inventory management and planning, manufacturing, production, and QA engineering on new designs, design modification, component selection, substitution, and change of configuration control.
LOCKHEED MISSILES & SPACE, INC., Sunnyvale, CA 1997-1999
Senior Mechanical Engineer
Mechanical design, and integration of the MILSTAR, A2100, STARDUST, and SBIRS solar array wing components, mechanism, and manufacturing support equipment. Utilized SDRC IDEAS 2-D, 3-D solid modeler to design these components.
Supported manufacturing to buid, test, troubleshooting, and manufacturing of the solar array components. Created LEO (Line Engineering Order), BOM, and DR (Discrepancy Report) and test documents.
Designed and analyzed the NASA SPACE STATION FREEDOM ATCS (Active Thermal Control System) ammonia heat acquisition and rejection system. Performed independent engineering research and analysis of the microgravity, two-phase ammonia fluid flow and heat transfer system and its components. Wrote computer programs to optimize single/two phase fluid lines and fluidic system architecture. Defined cavitating venturi, accumulator, shear-flow heat exchanger, RFMD Pump (Rotary Fluid Management Device), BPSOV (Back Pressure Shutoff Valve), and servo control valve design specifications.
Mechanical and thermal system design and integration of the solar array mast canister and containment box of the NASA SPACE STATION FREEDOM. Utilized TSS FEA solid modeling computer codes to calculate conduction and radiation heat transfer of these components. Sized components to meet thermal and envelope requirements.
Mechanical systems design, trade-off studies, development, and system integration of the miliatry aircraft pneumatic, environmental, propulsion (RB211 and GE T407), APU, wing de-icing, air cycle machine, a two-stages, variable speed axial compressor avionics cooling system using NARM refrigerant mixture, and the main engine bleed air control systems.
Developed components, systems, and equipment specifications. Evaluated technical proposals, supplier capabilities, and carried out technical discussion with vendors and customers.
EDUCATION
B.S. Mechanical Engineering, University of California, Berkeley, CA
Completed all graduate courses fulfilling Master of Sciences, Mechanical Engineering at Berkeley, CA
Design Controls and Total Quality System For Medical Products
Green Belt Trained in Design for Six Sigma, DFM/DFA/DOE
GDT (Geometric Dimension Tolerance) Certification
Parametric Technology Corporation, Certificates of training: Pro/E, Pro/Sheetmetal, Pro/Mechanica, Intralink
SDRC IDEAS TMG (Thermal Mesh Generation) – Thermal Design and Modeling - Certificate of Completion.
Honors: Dean’s List
Charles Holt Memorial Scholarship Recipient
Pi Tau Sigma & Tau Beta Pi Mechanical Engineering Society
California Alumni Association
Patents: Development of a Variable Diameter Tracheal Tube for Adult and Pediatric Patients, 2006. Patent # 8413659
Development of a high-torque, composite, aspiration flexshaft assembly for bone marrow harvesting, 2010. In-submission
Development of an Active Chemical Mixing System with Adjusting Osmolality. In-submission
Development of a Very Large Vapor Cycle System using NARM Refrigerant Mixture. In-submission.
References: Available upon request
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