Manager Engineer

GARY GUSTAFSON **** Red Oak Motley MN ***** ; ph 763-***-****

I also have an apartment Spring Park MN near Lake Minnetonka. acyppz@r.postjobfree.com

EDUCATION Excellent track record : solving problems using statistical methods. Hamline University St Paul: Double Major: Mathematics & Physics GPA 3.54 out of 4.00. Graduated Cum Laude, Phi Beta Kappa - I have 14 patents to date. Additional Training: Many years of work experience: additional training classes are beyond counting. IC Micro electronic processing, Photo lithography, ANSYS Finite Element Evaluation, Strategic Experimentation, Engineer as manager, Team Management Skills, Technical Writing, Specifications, Protocols, Procedures, Proposals, Quotes, Purchase Orders, Change Orders, Corrective Action, Job Responsibilities, Management by Objective etc... Photo Finishing Technology. Aerotech Motion Control, Stent Cutting and Programming, Parker PLC 6K Series 4, 6 & 8 axis Motion Control, Unitech Miachi, LASAG, Lee Laser Nd:YAG laser control. Laser Fundamentals, MEMS-Micro Electro-Mechanical Systems, 5 axis Swiss turning & motion control, Motion BASIC, Handbook of Analytical Methods For Materials, Geo-Metrics Dimensions and Tolerance, Process Control Capability and Improvement from IBM SKILLS Software Design and Manufacturing Technical/Presentation PC web Search Design Manufacturing Processes Cost estimating Solid Works Design of experiments Technical writing AutoCAD Electronic Assembly Technical presentations ANSYS(some Experience)Automated Machines >10 Customer relations Parker 6K Series PLC Machine Design & Debugging Proposal Writing Aerotech Electrical Equip Installations Project Management Smart Scope Optical UV Adhesives Research & Development Laser Marker Laser Cutting & Welding Six Sigma Golf Excel Mechanical Assemblies Time Studies

Microsoft Office Product Development Customer or Operator Training Electrical Enclosure Design/Fab Basic Research

Motion control to microns & arc seconds Create Manufacturing Procedures Pneumatic Systems & actuators Animal Testing

Stellar Technologies Cirtec, Brooklyn Park, MN (June 2016 – Sept 2016) Laser Engineer and CAD Design SolidWorks

• The original goal was to coach me to become the manager of the Laser Manufacturing Group.

• The existing manager would then move to sales. When Cirtec bought Stellar no sales positions were allocated.

• Reverse engineer laser Motion Control Software on manufacturing machines built by previous employees.

• Using Solid Works – Document the machine structure and the Input and Output programming functions.

• Establish IQ, OQ and PQ documentation to demonstrate manufacturing processes are under control.

• Cirtec announced no further engineering positions planed - my activities were put on hold. Heraeus Medical Components, St Paul, MN (July 2014 – Feb 2016) Sr CAD Design Engineer SolidWorks (included Large Project Management $650k)

• My primary project - develop Laser Processing to create .015” diameter “ball tips” on .007” diameter ground wires.

• First step was to travel to Switzerland and observe a similar process using plasma torch to make these ball tips.

• Second: identify laser equipment, process sequence and generate a purchase specification to build 5.5 million/ yr.

• Third: using a machine build service (Oak River) supervise the design review phases and the machine build.

• Fourth personally execute the Factory Acceptance Testing (FAT). I established this test to qualify the machines.

• Fifth: supervise the installation of facilities needed, shipping and installation of the equipment in Puerto Rico (PR).

• Finally in Puerto Rico test the first phase “semiautomatic” and then “fully automatic” processing machines.

• I successfully debugged the processing and machine issues. Several programming and mechanical bugs fixed.

• Operational (OQ) testing was begun, however due to power outages – no AC - humidity caused steel parts to rust.

• The laser ball tipping was a success however there were other problems – Cleaning, Forming and Assembly.

• This took the project back to the original wire straightening process. Too much variability both too hard and too soft.

• Other activity: Solid Works – design tooling and manufacturing equipment used in both R&D and Production.

• Produce 3D plastic parts used as tooling and used in preliminary design studies.

• My position was ended as the “Laser Ball Tipping” was put on hold and possibly moving to Costa Rica. Nortech Aerospace Systems, Blue Earth, MN (Aug 2013 – July 2014)

(Contract Position)

• The main products produced in Blue Earth were military electrical control system – cables – custom connectors.

• Using Solid Works – design tooling and molds used in both manufacturing and R&D.

• Produce 3D plastic parts used as tooling and design studies. Fortus 40mc 3D plastic Printer. Ultem and PVC

• Problem solves - manufacturing issues, design and build necessary tooling for operators. Preliminary SOPs. Widmer Associates Inc, Staples, MN (Early 2007 – June 2012) Manufacture a complete and functional 23 foot rotationally molded boat for the Navy. $3.5 Million Prototype; Government Contract. We were 3 key players. The Boss, General Manager /Engine Mechanic, myself Engineering. CAD Design Engineer & Finite Element Studies SolidWorks See: widmerboat.com

• Create / design the 7 Meter boat Rotational Mold using Solid Works. The mold was 10,000 lbs Aluminum & Steel

• Results of the design phase – 7 meter boat Solid Model and Product Assembly Drawings.

• Contract a complex Finite Element Study through a company Canada. Supervise this $140k study.

• Modify Hull Design to resolve issues identified by Finite Element Studies. Manage many assembly details.

• Characterize the benefit of hull flexibility - reduce jarring to equipment and minimize occupant injury.

• Coordinate the Tool Build through a Wisconsin Company. Communicate and resolve technical problems.

• Onsite at a company in Missouri to coordinate and support rotational molding the final Boat Hull & Deck

• Perform key roll: final assembly and testing of the deliverable boat to the Office of Navel Research. AltaMAR Laser and Control, Fridley, MN (2006 –2007) Shift Lead: Operate computer programmed high Power CO2 Lasers Cutting & Welding

• I sought this position to bridge a gap. Due to budget issues at LSA Laser; I was laid off.

• With my laser experience I could easily fill the company’s need to manage the night shift.

• The daytime manager was a friend from working at Spectralytics. I thank Rick Jackson for his help.

• Using high-powered CO2 lasers I cut tubular components for large playground sets, racecar frames, and various structural frames. Completed maintenance and repair on these CO2 lasers and motion control systems.

• Often, welded differential gears and parts for two different popular 4-wheeler - snowmobile companies.

• My responsibilities included CNC programming each product produced on my shift.

• AltaMAR also built custom and off the shelf machines. I did on site training after the sale to instruct the new owners on programming and safety procedures using high-power CO2 laser cutting systems. LSA Laser, Plymouth, MN (2001 –2006)

Laser Job Shop, Laser Weld and Cut: primarily medical products. Project & Manufacturing Engineer:

• Responsible for new products and manufacturing process: resolve difficult customer projects / requests.

• Responsible for developing project schedules and work breakdown with job assignments.

• Resolving many difficult customer requests lead to new and ongoing production projects for the company.

• Manage production projects from shop floor problem solving to customer interface issues. Visit Customers.

• Establish control charts motion accuracy, programming revision change and control; Laser tuning, equipment maintenance and records. Establish and control operating procedures. Train employees as required.

• Design using Solid Works; coordinate the build of and maintenance records for special production tooling.

• Laser maintenance: record performance, tuning as required and flash lamp changes cooling system repair.

• Installed a clean room vacuum cleaning system. External vacuum, plumbing pipe and internal vacuum adapters.

• Build Production Work Stations. Built at least 9 computer controlled laser welding and cutting machines.

• One key machine was a laser tube cuter, linear accuracy in microns and rotational accuracy to arc sec.

• Lead in the development of production, maintenance and procedures manuals. Remmele Medical, Big Lake, MN (Medical Products Machining) (1998 - 2001) Senior Manufacturing Engineer - New Business Development

• I was hired to bring laser micro machining skills and equipment into Remmele’s Micro Machining Division.

• The company has a large business making parts using Swiss turning 5 axis machining and precision drilling.

• Laser cutting and welding would allow manufacturing much smaller parts.

• My efforts as supported by Remmele yielded a very precise laser cutting machine. The human hair is about .003 inches - the cutting beam size was less than 1/3 the diameter of a human hair. (.007”)

• Remmele chose to market the company and reduce R&D expenses. I had several weeks to find another position. Spectralytics, Dassel, MN (1995 - 1998)

Stent manufacturing -- Stent sales > $3 million per year Project Engineer promoted to Stent Group Manager

• Developed, built and patented a laser cutting machine to make stents for angioplasty.

• Sole inventor patent #5,852,277. I wrote the patent and consulted with lawyers.

• Built a manufacturing business with sales of $65k per week more than $3 million per year!

• As Stent Group Manager I managed 9 employees; 3 sometime 4 shifts per week.

• Wrote the laser cutting programs, established operating and quality control procedures.

• Developed a chemical cleaning procedure. There was an oxide created due to the laser cut, this oxide affected the electro polishing process. Removing the oxide was critical to having a successful product.

• Our major customer was in Israel. I traveled there in 1996 to establish quality procedures.

• This project was at the front of the stent market. Johnson and Johnson had a patent controlling US sales.

• My job was to create a process to make the manufacture of stents viable. I was successful at developing the process and building a manufacturing business with a budget of about one half million.

• The patent went through infringement litigation with Cordis/ J&J in 2009. The damages award was $22.35M.

• Left Spectralytics to take an offer from Remmele, I perceived Remmele to be a more stable company with better income and career opportunity. Specralytics was having difficulty and sold to Preco. Hutchinson Technology Inc: Hutchinson, MN (1993 - 1995) Manufacturer of Suspension for computer hard drives. R & D Engineer - I have several patents with HTI.

• Develop the next generation of suspension technology for hard disk drives.

• My experience with micro-electronics at Honeywell and at Becton Dickinson Vascular Access lead to a transfer of micro-electronics technology into computer hard drive suspension technology.

• Stainless Steel has stress & yield issues. Beryllium-Copper yielded better repeatability, lower fly height!

• The solution was a laminate structure Beryllium-Copper with Stainless Steel using a polyimide adhesive layer. This produced the spring conductors and using SST as the base material we resolved a downstream manufacturing issue to interface with existing manufacturing processes.

• This new suspension yielded significantly better fly-height performance, coupled with a better magnetic disk surface material; computer drives went from 100s of Mega Bytes to 100s of Giga Bytes. Viggo Spectramed, Inc.: Oxnard, CA (1992 - 1993)

Manufacture of ex vivo pressures used for critical hospital care. Contract Engineer

• My job was to find a way around a patent infringement issue. I was a patent consultant.

• The company was in a patent lawsuit. Threatening to close the company 480 employees.

• The company did offer me a position but I could see the lawsuit was going to fail.

• After this I moved back to Minnesota.

Becton Dickinson Vascular Access Division: Sandy, UT (1988 - 1992) R&D Project Engineer Promoted to Project Manager Level 9

• Hired into an existing project with a silicon pressure chip - drift in the pressure signal.

• The chip problem was resolved by identifying sodium contamination, we employed a new vendor.

• Week long Anesthesiology class at the learning hospital Gainesville Florida. Anesthesiologists were our intended customer. Part of my job was to understand their needs and make contact with anesthesiologists and find future locations for Human studies. My responsibilities included working closely with the Hospital in Salt Lake.

• Managed the Pilot Manufacturing Plant (9 people). The automation target was 750,000 units/yr.

• Spearhead automation process / procedures; successfully moved production tooling and product performance into a long term workable solution. Pressure sensor offset drift was a problem.

• Identified a patented way to reset offset while the probe is in the patient. In Vivo Re-Zero. #5,133,358

• Promoted to level 9 Product Engineering Manager.

• My Supervisor (Project Director) went to France; I was asked to take responsibility for the entire project.

• This responsibility was 15 people: 9 operators / technicians and 6 engineers.

• There were several projects, Pressure Chip Manufacture Test and Procurement, Pilot Plant Automation, Test Sample Build and Sterilization, Electronics - Clinical Monitor Interface, FDA 510(k) Protocols, Animal Studies - Surgery, Animal Care and Data Collection. Performance Evaluation - Pass Fail Criteria. Obtain Clearance for Human Studies. Follow-up and obtain the In Vivo Re-Zero patent.

• The Animal Studies were conducted at the Artificial Hear Lab, Salt Lake. Where Barney Clark’s Heart was made.

• Becton Dickinson bought the private Company Vascular Access. BD decided that 750,000 procedures per year was not enough. The product would become a radial artery measurement tool with millions of procedures per year, however we were competing in an $8 dollar market with a $27 dollar product. I spoke with my contacts at the hospital and took a consulting job in California. As the project was terminated. Honeywell Solid State Electronics Division: Plymouth, MN (1980 - 1988) Entry level R&D to senior level R&D Project Engineering

• Developed silicon pressure sensors for Air Speed and Altitude indication for Aircraft.

• R&D - New Project Development to build a pressures sensor for the Space Shuttle. 1 year proof of concept.

• Deputy Technical Director for the follow on contract awarded. I managed a $7 million project for NASA.

• Responsible for the SSME (Space Shuttle Main Engine) Silicon Pressure Chip Design.

• Responsible for Cryogenic Temperature Testing up to 10,000 psi. Obtained a Liquid Helium Cryostat.

• Design / Build a Pressure Sensor Family for the SSME - 500 inch H2O to 10,000 psi full scale.

• Developed a carburetor for the Space Shuttle Main Engine. Pressure devices to managed Liquid O2 and Liquid Hydrogen flow to the main Engine.

Included in project Hands On & management skills: I built my own house as general contractor. Using a $50,000 construction loan, managed the overall plans, foundation, rough framing, concrete floor, shingles, sheet rock and siding. I did many projects myself. I did the electrical, plumbing, in floor heating, air handling for AC and air exchange, insulation wall and ceiling, finish carpentry – hang doors, floor molding and trim, installed Jacuzzi tub, all bath and kitchen fixtures, installed all lighting. Managed the finances and closed with the bank in 10 months. Reference List

John Wirght Heraeus Medical Components, St Paul

Coil Winding Product Engineering

Cell 651-***-****

Leo D. Katzner Katzner Consulting LLC

MBA Chemist

Consulted at Heraeus Medical Components

Cell 612-***-****

Gabino Nieves Heraeus Medical Components (in Puerto Rico) Stylet Product Development

Cell 939-***-****

Mark Nordquest Aerospace Systems A Division of Nortech Systems Sales and Engineering Manager My Second supervisor Wk 507-***-****

Cell 507-***-****

Steve Dodge Aerospace Systems A Division of Nortech Systems The first supervisor

Cell 507-***-****

Stanley Widmer President Widmer Associates Inc.

Cell 320-***-****

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