Aerospace Engineering Security Clearance

Alexander Klein Safari

Mobile: 949-***-**** Email: ****.*.******@******.***

US Citizen with active clearance Fort Lauderdale, FL

Linkedin: linkedin.com/in/alex-safari-6116603

Professional Summary:

A professional with a master's in aerospace engineering with extensive experience in the aerospace industry and in-depth knowledge in cable and wire harnessing.

Experience in Full 3-D Cable & harness Route using SIEMENS CAPITAL LOGIC and CAPITAL HARNESS along with CREO V6 3-D Cable-Harness Route with proper tie-down and fastening techniques.

Possess a high knowledge of Avionics and Avionics component piece parts utilized in the design and manufacture of cable assemblies such as MS38999 connectors and contacts as well as MS2750 harness and TP wire types.

Advance Super Dense Electronics Packaging, including PCBs; Backplanes: P.D.U; Chassis & Rack Designs with all relevant MIL qualified components, either COTS or Custom Design.

Developed cable-wire harnesses with comprehensive details, confirming newly developed Interconnect Diagram and Connection between the Racks to other areas of design interest.

Designed and Created Test Fixtures for various printed circuit board assemblies with different technologies with all detailed assembly and manufacturing drawings with necessary orientation views showing the assembly's stage and progress.

Education:

MS Aerospace Engineering

SDSU Candidate San Diego, CA

BS Mechanical Engineering

The University of Michigan Ann Arbor, MI Credit Transfer to WMU

BS Aviation & Aircraft Engineering Technology

Western Michigan University Kalamazoo, MI

BS Electro-Mechanical Systems / Mechatronics Extension Studies

University of California San Diego, CA

Cad Skills & Owned Software:

CREO 7.0: CREO-CABLE, PRO-DIAGRAM, PRO SHEET METAL

PRO INTRALINK: PRO WINDCHILL

UNIGRAPHICS NX 11 NX-1946

SOLIDWORKS 2020

ALTIUM PCB

TEAMCENTER: PDM Cosmos FLOWORKS With Thermal Simulation

ANSYS ICE-PAK: Electronics Thermal Simulation

ANSYS rev 13.0

ZUKEN E3 + Cabling Solutions

SIEMENS CAPITAL 2207

Security Clearance:

Security Clearance

Professional Experience:

Mechatronics Engineer

RAYTEON Systems Tewksbury, MA May 2023 – Present

As one of the Technical Staff members of the “Peace-Keeper” assignment, have designed, developed, and completed new and fully re-packaged and upgraded Electronics enclosures with extensive light alloy aluminum protrusion and machining with correct in-place thermal fins and heat paths.

Rack design; Backplane design with optional hot insertion PCBs. High Temperature Space Qualified Components. Selection as well as correct connector as part of the Future-Bus interconnect & communication

Re-developed cable-wire harnesses with comprehensive details, confirming newly developed Interconnect Diagram and Connection between the Racks to other areas of design interest.

Full 3-D Cable & harness Route using SIEMENS CAPITAL LOGIC and CAPITAL HARNESS along with

SOLIDWORKS 2020 3-D Modeling and Electrical for 3-D Cable-Harness Route with proper tie-down and fastening techniques, satisfying all MIL and manufacturing requirements.

Documented all processes and procedures. Created Engineering Change Orders with suggested solutions.

Teams database for all Electrical Systems with wire Domain, integration, mechanical, and harness interconnects.

Mechanical Design

MERCURY Systems Torrance, CA Jan 2022 – May 2023

Designed, developed, and completed all new LRU-I and LRU II, the new fully re-packaged and upgraded AVIONICS & GUIDANCE Control, upgrading the current on-board systems.

Extensive electronics packaging, including mechanical PCB design, usage of ORCAD for schematics and PCB design, fully thermally conduction Chassis system with extensive Aluminum alloy protrusion and machining with correct in-place thermal fins and heat paths.

Rack design; Backplane design with optional hot insertion PCBs; Selection of Space Qualified VPX connector based on Future-Bus interconnect & communication. Interconnect Diagram and Connection between the Racks and other areas of design interest along with full 3-D Cable & harness Route, proper tie-down, and fastening techniques.

Extensive use of SOLIDWORKS 2020 with CABLE ROUTE; PDM database for all Electrical Systems with wire Domain, integration, mechanical, and harness interconnects. Some usage of the PTC CREO 4.0 with HARNESS_3-D ROUTE Module along with Full Electrical and 3-D Harness Wire Route were executed as well, satisfying the supplier’s database style demands.

Mechatronics Design Engineer

NASA & PARSONS Torrance, CA Houston, TX Mar 2021 – Dec 2021

As one of the primary Staff members of the “LMSI “, [ Launch Manifest System Integrator], have been able to package several small Satellites and, submit them as the second payload for the current large space vehicles, launched by NASA and ULA, about 5 to 7 annual launches, taking advantage of the leftover Space Vehicle performances.

Have completed extensive AVIONICS electronics packaging, Chassis Design, and the mechanical PCB.

Design along with all corresponding Harness & Cable Design/\Route/s, delivering signals and power for all telemetry; Power; Status Monitor as well as Ground Support data.

Designed and completed all 3-D Cable Route/s, space approved and Qualified Connector and Back-Shell selections with corresponding 2-D Flats; BOM with all Interconnect diagrams and Shield Terminations. Implemented ARC Technology for best EMI performance as well as elimination of all nonrelevant items. Extensive use of SOLIDWORKS 2020 CAD with CABLE ROUTE; PDM database

Some additional modeling and 3-D Cable Routes were performed via CREO 5 /\ CREO CABLE; WINDCHILL for other electrical and mechanical integration via harness database. Work Samples are available on my LINKEDIN account.

Mechatronics Design Engineer

EDWARDS LAB Irvine, CA Feb 2020 – Mar 2021

Extensive Electronics Packaging for brand new Patient Monitoring System.

Extensive Electro-mechanical re-packaging for the new generation of advanced hemodynamic monitoring solutions.

Duties included Power Supply and Power Distribution cabinetry including all high-power cables as well as all other Custom Cable & Harness designs and attaching the Instrument to the patient with all custom connectors. Task including 3-D Route, 2-D Flat along with all relevant Interconnects.

All custom connector details with WIPE contact action, and MALE-FEMALE secure halves.

Completed all instrumentation interconnects for all pneumatics and Liquid Coolant /\ Discharge. Component selections such as custom quick disconnect custom barb and, custom tubing. Creation of 2-D drawings for all Printed Circuit Board Outlines, based on given real estate using “U” Size. Extensive usage of SOLIDWORKS SUITE 2018 along with SOLIDWORKS Electrical with SIEMENS TEAMCENTER as well as PDM database management.

Mechanical Designer

TERADYNE North Reading, MA Mar 2019 – Feb 2020

Extensive Electronics Packaging for new Capital Equipment, FPGA, and another high-end chip TEST & QUAL.

Duties included Power Supply and Power Distribution cabinetry including all high-power cables and all others.

Cable & Harness designs, with 3-D Route, 2-D Flat along with all relevant Interconnect diagrams.

All interconnect pneumatics and Liquid Coolant Route and plumbing. Component selections such as custom quick disconnect custom barbs, custom tubing, etc. Creation of 2-D drawings for all Printed Circuit Board Outlines, based on giving real estate and “U” Standard. Extensive usage of SOLIDWORKS SUITE 2018 along with SOLIDWORKS Electrical

with SIEMENS TEAMCENTER Center and PDM database management.

Mechatronics Engineer

RAYTHEON TECHNOLOGIES Goleta, CA & Tewksbury MA Jul 2016 – Feb 2019

Designed and modified off-the-shelf 19-INCH Electronics Rack, satisfying the custom application with all mounts, cooling trays and racking all shelved electronic instrumentations, connecting to the command center via all Cable & Harness designs, 3-D route with 2-D flats for all power and interconnects.

Extensive use of CREO 4/5; CREO-CABLE with complimented Electrical /\ Harness Design to do all 3-D Route Component sub-assembly; simplified rep with some occasional “COPY-GEOM “, for environmental references, converting the 3-D route to 2-D Flat along with P2P (Point to Point), tabulations with net & signal name for all Test Site. Occasional C+ and C++ programming. Occasion ACAD 21 was also utilized per the supplier’s MCAD tool request. ZUKEN net-list creativity and preps for XML import into CREO-CABLE. INTRALINK-PDM and some Team-Center databases manage usage.

Extensive use of ALTIUM R-17 PCB and the ECAD tool handshake in between MEs & EEs. Extensive Electronics Packaging: Design; Analysis along with Harnessing for the DPICC AAMD and AAMG Programs. Relevant structure and hardware shock & vibration analysis using ANSYS Rev-13. Import-Export 3-D models in between CREO and ANSYS and vice versa with quite a bit of model modifications, over-coming ANSYS fine-MESH scenario with Free-Body scenario.

Performed all proposals as well as the actual Electronics Packaging with Electro-Optical alignment and optimization with digital sensor conversion/s.

Modified/Updated the present CRYO-GEN Cooling Systems 3-D models using CREO Interactive

Surface Design Extension, combining parametric modeling with the flexibility of free-form surfacing.

Modified/Updated the present Compressor tanks for DEWAR Cooling Systems

Designed and developed Shock and Vibration Fixtures for various Dewar Configurations

Designed and developed the Alignment and Wire Bond tool, as the Hold-Fixture-Check

Mechatronics Design Engineer

GE HEALTHCARE Issaquah, WA May 2015 – Jul 2016

All Electro-Mechanical Design, re-packaging, and Interconnects for all ongoing Microscopy Instrumentation and hardware with relevant 3-D assembly procedures for ease of manufacturing with small C+ and C++ programmers.

Conducted chassis and PCB level Thermal Analysis, verifying the system’s thermal performance as well as

FEA’s requirement using ICE-PAK thermal simulation package by ANSYS. Routed & Re-Designed new cable assemblies with properly assigned POWER/SIGNAL pins with full RoHS Compliancy as well as FDA and other in-place certifications.

Created a comprehensive database with a component library including all connectors with back-shells. Utilizing Mentor Graphics Capital Harness XC Design & Development with a full 2-D platform.

Created layout and detailed design for various motion control PCB/s with full component assembly including all detailed documentation and drawings. Utilizing CREO-5 and UNX 11.0 as primary 3-D CAD software.

Mechatronics Design Engineer

MICROSOFT Redmond WA Nov 2013 – May 2015

On-going: Cable & Connector Design; Development and Off Shelf selections of connectors, Harness, and Cable assemblies for various SENSORS and H.I.D., (Human Interface Devices) new development, work in process and, in-production. Generated Interconnect Diagram/s with relevant BOM. Introduced and proposed ‘ARC’ cable jacket Technology enhancing the EMI/EMC cable protection leading to cost reduction and eliminating the Ferrites on Power cable assemblies. Created and routed power and signal cables including lay-out through various KINECT sensors.

Implementation of full mechanical design for various PCBs with preparations of EMN EMP data exchanged, converting ECAD to MCAD models in between Mechanical, CREO, and PCB Designers via ALEGRO.

Numerous Heat Sink design/upgrade developments with retention mechanisms and Air-Flow analysis for all Electronics with air-cooled/Fan-cooling techniques.

Extensive use of ICE-PAK. Modified and Created 19 INCH Electronics Rack as the Cloud Server Rack, the 18 U to 42 U reachable space with special attention to customizing the FAN Tray, the Lift Gate, and the vertical cable management bar to house the liquid cool plumbing.

Mechanical Design Engineer, Consultant

EXELIS NASA Rochester NY Houston TX May 2013 – Nov 2013

Completed all Test Set-up/s & Fixtures for all needed Harnesses/Cables to be used during CRYO and other extreme environmental tests on the subject instrument PTC’s PRO CABLE-CREO / WF5 as well as PRO/MECHANISM were all utilized as the prime CAD tool.

Created and routed cables including lay-out through the Test Chamber’s P-P, [Penetration Plates] as well as the He and LNe shrouds. Completed thermal isolation and pre-heat before entry to the harsh environment.

Created layout and detailed design for all Controllers; Instrumentations utilizing 19-inch Rack and Chassis as well as creating all detailed mechanical models as well as 2-D detailed drawings using PTC’s PRO/E CREO 2.0

Mechatronics Design Engineer, Contractor

BLUEORIGIN Kent, WA Jun 2012 – May 2013

Completed all Electro-Mechanical Packaging and Interconnect for SPACECRAFT application.

Structural and Thermal Analysis for various AVIONICs and Space-Craft Electronics Packaging Using ANSYS and ICEPAK.

Routed & distributed all spacecraft SIGNALs and POWER cables with proper Shielding & Thermal Sleeves for extreme environmental exposure using PTC’s PRO CABLE-CREO/WF5 CREO 2.0/3.0

Extensive Cable assembly Thermal & Radiation analysis using ANSYS and ICEPAK.

Created all routed cable layouts, and designs along with Cable Flat drawings and BOM.

Created a comprehensive database with a component library including connectors, back-shells, and spools with proper parameters.

High knowledge of Avionics and Avionics component piece parts utilized in the design and manufacture of cable assemblies such as MS38999 connectors and contacts as well as MS2750 harness and TP wire types.

Created layout and detailed design for AVIONIC Chassis with all Interconnects and full conduction cooling techniques including all details and drawings for all hug out AL chassis as well as OTS channels Advanced Network interconnects and Harness/Wire for all AVIONIC devices such as Primary & Secondary ADAHRS, [Air Data Attitude Heading Reference System], COM Radio, PITOT read-out, AF GPS; AF-ARINC using USB Ethernet, PMC, VME and VXI card controller system.

Mechatronics Design

LOCKHEED-MARTIN NASA Littleton CO Apr 2011 – Jun 2012

Completed all Electro-Mechanical Packaging and Interconnect for the ORION Emergency Crew Recovery space vehicle, including all system diagram/s: Inter-Connect/s, Cables, connectors, and Wire-Clamps.

Structural and Thermal Analysis for various AVIONICs and Space-Craft Electronics Packaging using ANSYS and ICEPAK. Routed & distributed the spacecraft SIGNALs and POWER cables with proper Shielding & Thermal Sleeves for any extreme environmental exposure using PTC’s PRO CABLE-CREO/WF5 & CREO 2.0/3.0. Created all routed cable layouts, and designs along with Cable Flat drawings and BOM.

Created a comprehensive database with a component library including all connectors, back-shells, and spools with proper parameters. High knowledge of Avionics and Avionics component piece parts utilized in the design and manufacture of cable assemblies such as MS38999 connectors and contacts as well as MS2750 harness and TP wire types.

Created layout and detailed design for AVIONIC Chassis with all Interconnects and full conduction cooling techniques including all details and drawings for all hug-out AL chassis as well as OTS channels. Advanced Network interconnects and Harness/Wire for all AVIONIC devices such as Primary & Secondary ADAHRS, [Air Data Attitude Heading Reference System], COM Radio, PITOT readout, AF GPS; AF-ARINC using USB/Ethernet, PMC, VME and VXI card controller.

Mechanical Designer, Consultant

RED DIGITAL Cinema Irvine CA May 2011 – Apr 2012

Redesigned and Re-layout with validation and confirmed PCB assemblies used on high-resolution digital camera’s primary PCB boards. Custom mechanical fixtures for holding and exposing the top assemblies to the desired/designed with maximum allowable temperature along with shock/vibration test on a shake table.

Extensive use of ICE-PAK by ANSYS software for all thermal and structural simulation/validations Designed and Created Test Fixtures for various printed circuit board assemblies with different technologies with all detailed assembly and manufacturing drawings with necessary orientation views showing the assemblies stage and progress.

Revised PANASONIC pick & place, MC-400 along with GO NO-GO systems for the unique application.

Completed the designs with detailed drawings for all assigned fixtures, alignment tools, and part- in-place pieces using machined, extruded as well as off-the-shelf components.

PRO ENGINEER WF4.0 & WF5.0/CREO, SOLIDWORKS 2010 CAD were utilized.

Mechatronics Engineer & Designer

ITT DEFENSE L3-HARRIS Clifton, NJ Oct 2009 – Apr 2011

Comprehensive Electro-Mechanical Design, analysis, and Packaging for a military program

Utilized PRO/ENGINEER WILDFIRE 4.0, 5.0, and PRO/DIAGRAM-PRO/CABLE to create the layout and design of Cabling & Harnesses with related Spools for all Harness interconnects within the Black Box.

Completed all designs with detailed drawings for various RF Modules, Circuit Cards, and motherboard assemblies based on 1U and 3U rack mount electronic instrumentations and components. Utilized the ANSYS ICE-PAK and FLOWWORK CFD tools to define and validate the AIR-FLOW through the entire chassis under design and development.

Created all necessary drawings and documentation showing different assembly stages as well as the manufacturing work in progress.

Mechatronics Designer Engineer

DRS Technologies Danbury, CT Feb 2008 – Oct 2009

Completed the creation and design of cables and Harnesses with all related Spools for all the instrumentations interconnect for comprehensive Command Control Custom Cabinet design for NAVAL Systems application.

Completed the assigned NAVAL project with full mechanical and weldment designs, detailed drawings, and documentation for custom 1U and 3U rack mounts fully populated with various designed and developed electronic instrumentation.

Completed the Route for all AC & DC power supply, all fiber-optic/s, as well as critical control command signals. All the CABLE routes were conducted with PTC PRO/CABLE.

Completed the design and packaged VME & COMPACT PCI BACKPLANE/s interconnect with thermal evaluation and simulations using ICE-PACK software Utilized PTC’s PRO/CABLE, PRO/ENGINEER WF 4.0 as well as RS Designer

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