Design Engineer Mechanical

DARKO PONJEVIC

ME/Mechanical Design Engineer/PRODUCT DESIGN/CATIA/ENOVIA/NX/TEAMCENTER

GENERAL SKILLS

Highly efficient, motivated and talented mechanical design engineer with over 15 years of experience in aerospace, automotive, optics, power & gas energy industry. Have extensive experience in aero-derivative gas turbines, aircraft interiors, payload, product design, structures, and systems design as well as quality. Have excellent ability to communicate effectively with all levels of the organization and excellent knowledge and experience in the field of development and design presentation reviews, design, FEM analysis, improvements, and weight reduction studies.

- Brilliant Knowledge of Meta - VR Headsets Prototypes.

- Outstanding Knowledge of Siemens / Rolls-Royce Aero-Derivative Gas Turbines.

- Excellent Knowledge of Boeing Aircraft, 747-8 Freighter & Intercontinental, 767 FedEx & 777-300.

- Excellent Knowledge of Bombardier Global 5000 Aircraft & NTS Top Pylon Leap Frame Project.

- Brilliant Knowledge of EGT LED Continuous Lighting and Thorburn Piping and Ducting Systems.

- Strong Knowledge of General Machining, Drilling, Punching, Milling, Lathe Work.

COMPUTER SKILLS

- CAD Software Packages: AUTOCAD, CATIA V4, CATIA V5, NX, SOLIDWORKS & ZERO ERROR

- FEM Software Packages: ANSYS, COSMOS, NASTRAN, PATRAN & PC LAMINATES

- MICROSOFT OFFICE Packages: ACCESS, EXCEL, POWER POINT & WORD

- Operating Systems: ALTAVISTA, WINDOWS 2000/XP, WINDOWS10 & UNIX

- Product Management Software Packages: ENOVIA (PLM), PDM, SMART TEAM & TEAM CENTER

- Program Languages: C++ & MATLAB

- Vision Software Packages: FLY THRU & IVT (Integrating Vision Tool)

WORK EXPERIENCE

Meta / H10 Capital, 1180 Discovery, Sunnyvale, CA 94089, USA

ME Manager - VR Optical Engineering - OMAP Team, Consultant

September 2022 / January 2024

Assisting Asia based design firms and fabricators to deliver test fixtures per specifications.

Experience in supply chain and manufacturing to develop hardware tooling/fixture and bring process and technology into mass production.

Oversees supplier performance for test fixtures to ensure system integration and compliance with requirements.

Close interaction with many different teams both in Asia & USA including product design, hardware test engineering, and various business teams.

End-to-end ownership of full optical metrology mechanical design and development, from concept through launch.

Collaborate with lens engineering, display, system engineering, process and other cross-functional teams.

Collaborate with system PD team to consider device under test design and manufacturing tolerance for Optical Metrology tools.

Lead development and process explorations for improving design for mounting, and assembly tolerances.

Managing test fixture requirements, build, test and validate design elements for manufacturability and structural integrity.

Explore novel opto-mechanical structures for Metrology tools and optimize for repeatability, performance, reliability and cost.

Establish and refine the mechanical design process, best practices, and/or tools for the organization.

Sets deadlines, assigns responsibilities, and monitors and summarizes progress of project.

Providing on-site support for test during new product development at different partners.

Evaluating technical design reviews (PDR, CDR, PRR, TRR & SRR) with internal-external vendors as well as source qualify for necessary mechanical tools, fixtures and equipment required to support worldwide production and test of service modules.

References & Recognitions are available.

Meta Projects / Tasks:

- 3D Print Dummy Stinson EVT2 DUT with Alignment Feature

- Cone Baffle Fixture

- Conversion Plate for PST Station

- Defeatured Eureka Shell Model for VFGE Fixture Development

- Defeatured Model 1 HMD Rev2 CAD (Varifocal) for VFGE Fixture Development

- Design Holder for Dynamic Distorsion Measurement

- EPD Metrology Optical Module Characterization

- Fixture & Alignment Jigs for Miramar & Ventura

- Fixture for AVP

- Fixture for IMHR Ref Lens

- Fixture for IS Lamp

- Fixture for Radiant XRE Lens

- Hazegard Mount for Cardiff L1 Lens (Convex Side UP)

- Holder for Radiant Vision Camera

- Improved Alignment Jig V2 for Varifocal Eyecup & Model HMD

- La Jolla, MALT Lens Holder

- Lens Tray Design for Zygo Auto Flat Tester with HYC

- Luphoscan Fixture for Stinson Lenses

- Neon - Metrology Fixture & Alignment Jig for Neon OM

- Neon - Metrology Hardware Review

- MALT Holder for Metrology Measurement

- MALT Holder for Project Alki

- MALT Mount for Stinson L2

- MALT Fixture for Swithch Module

- Miramar (Quest-2), Housing CAD for VFGE Tester

- Model HMD DUT Holder Review

- Part for Blocking Light

- Review for Eureka MOT-Tester for EVT1-DEM

- Sheet Metal Part with Rectangular & Circular Cutouts

- Stinson CGH Lens Fixture Design Review

- Stinson EVT2 Headset Design Verification

- Stinson Headset 3D Print Alignments (58, 63 & 68 mm IPD)

- Stinson L2 Luphoscan Fixture

- Stinson P1 HMD Holder for Gamma Scientific

- Stinson Zygo VFA Lens Fixture Design

- Varifocal + Cardiff T3 Mounting Fixture for Gamma Scientific & Ghost Tools

- Varifocal Defeatured Model HMD CAD for VFGE Fixture Development

- Ventura HMD EVT1 - Validation Readiness

- Ventura EVT1 Alignment Jig

- Ventura Check the Fixture Design from Vendor

- Ventura VROE - Fixture & Alignment Jig for Ventura P1 HMD

- Ventura VROE - Measure Ventura CW Candidates

- VFGT Test Carrier Review (Quest-2 & Quest-3)

- VR OMAP-ME Support Intake Form, Cardiff & Stinson

Meta / H10 Capital, 1180 Discovery, Sunnyvale, CA 94089, USA

Senior Mechanical Engineer – Product Design, Level 5, Consultant

January 2022 / September 2022

Support Development of new concept & technologies for next generation in Optic and Displays.

Determine the function definition & main requirements in various conceptual design stages.

Determine & Coordinate the functional interface relationship and performance corresponding among various systems.

Experience with metrology optical lens & mechanical testing.

Work with other mechanical & optical engineers, explore design space and tradeoffs.

Document all design, simulation and modeling materials and communicate cross the team.

Familiar with Optical-Mechanical components fabrication and materials.

Product Design, Hardware prototype skills & build.

Familiar with fast prototyping tools and capabilities, such as 3D Printing & CNC.

Demonstrate extreme hands-on technical expertise on various tooling components and systems, understood key factors in both the development, process qualification and manufacturing aspects of secondary operations, metal or plastic CNC machining, welding, glue dispensing, insert molding, sheet metal fabrication, sub-assembly processes, plastic painting, printing, CMF (color, material & surface finishing - blasting, polishing, PVD coating or anodization).

Make recommendations to modify part specifications & tolerances as necessary to adapt development processes for high volume production and support cost effective production.

Work on mechanical design, fixture and prototyping build.

Experience as a Lead of Fixtures-Prototype Engineers’ Group.

Extremely Skilled with Siemens NX-Cad and Teamcenter-PLM tools.

Meta Projects / Tasks:

- Adapter for Arcata Pogo Modul Fixture

- Autofocus Autocollimator Tooling

- Cardiff L1 Convex Side UP, Mount for MALT

- Cardiff Lens Module with L1 on Top, Mount for MALT

- Cardiff L2 with S1 Facing UP, Mount for MALT

- Cardiff P1.2 Defeatured HMD CAD for VFGE Fixture Development

- Cardiff T3 Lens Assembly Fixture

- DUT Holder-Fixture for Gemini

- EBMT, SFR Pattern Holder

- Fixtures for GRIN-LC / Switch OM / HMD – Cardiff T3 Eyecup

- HMD Holder for External HMD

- HMD-P1 Holder for Gamma Scientific

- IMHR Fixture for OFF-Axis Ref Lens

- IMHR Gauge Block for Arcata & Stinson

- IMHR Lens Holder

- Lab Illumination Tester Holder

- Lens Module Holder for Rotation Stage, Cardiff

- Mounting Fixture for ZWO Camera

- Mount for Arcata Headsets on Golden Eye V2

- Mount for Cardiff Lens Module & D-Film to URS150BPP Stage

- Mountable T3 Display Housing Fixture to Support Lens Module Testing, Cardiff

- MR Fixture for Stinson HMD

- Special HMD Fixture for Gamma Scientific Tool

SIEMENS Canada / Easi, 9545 Chemin de la Côte-de-Liesse, Dorval, QC, H9P 1A5, Canada

Product Definition Design Engineer - Modeler, Level 5, Consultant

October 2015 / Jun 2020

Siemens Programs: Aero-Derivative Gas Turbines SGT-A45, SGT-A65 & IRB211, TRENT, AVON from former Rolls-Royce, Power & Gas Division, Energy.

Product Definition, designing parts, assemblies, installations and modules with Siemens NX Cad & Team Center, Systems in a high pressure, temperature and vibration environment for SGT-A45 and SGT-A65 as well as Industrial Trent and IRB211-Spider (LP, IP & HP Bearing Support Structure).

Develop the function definition & main requirements in various engines conceptual design stages.

Determine & Coordinate the functional interface relationship and performance corresponding among various systems.

Oversee design reviews, statement of work ‘SOW’, creation of 3D Cad models and drawings, managing & making changes to Teamcenter as well as creating or modifying workflows and Releasing in Teamcenter.

ICD for Industrial Trent Marinization, Compressor, IPT shaft & shaft material change.

Front and Rear Shaft, Rotor.

LP, IP & HP Bearing Housing Jacking Holes, Ducting, Vanes and Modification of Turbine Blades-Cooling Holes.

Perform and coordinate mechanical design calculations and functional analysis on advanced casting Gas LP, IP & HP Compressor Casing, Inlet & Outlet Casing, Combustor & Turbine Casing, Rear Mount Ring Structure and Exhaust Casing.

Front & Rear Flanges, Bosses, Bushes, Sheet Metal Forming of Brackets and Plates.

Defines and controls the functional and physical interfaces between the propulsion systems as well as develop product requirements specifications of drawings per, ASME, ANSI Y14.5 or ISO 1101 in conjunction with internal and external customers.

Knowledge of interpretation of specifically geometric tolerances ‘G&T’ and practical application of Industry codes, certification requirements and standards for different regions and countries (API, ATEX, PED, CSA, NACE, ANSI, ASME, ISO 21789, FAA Part 25/EASA CS-25 & ARP4754A).

Supporting Industrial Siemens Gas Turbine SGT-A45 production & development program phase, PDR, SRR, CDR, PRR & TRR including system integration, engine system development, instrumentation, testing, mounting, attachments and wiring of cables & connectors of electronic devices such as Accelerometers, Accelerometer Junction Boxes and Temperature Sensors (Thermocouples and Thermocouple Boxes).

Remastering 3D parts, assemblies, installations, modules, and creating 2D Drawings from former AVON Rolls-Royce Program.

Delivers engineering drawings such as P&ID (process and instrumentation diagram), general arrangement drawings, assembly drawings, redline markup, work instructions, or work packs, construction instruction, API data, communication sheets and component/equipment datasheets.

Investigates, develops and presents Engine Externals - Powerplant (Clamps, Hoses, Tubing Fittings & Tubing Air/Oil Lines) within a variety of systems in various engines including Drain, Fuel and LP, IP, & HP Bearing Lubrication Lines, Fire Suppression, Bleed Air Systems, Manifold, Nozzles, Valves, Oil and Fuel Filters.

Support external team in India and perform Quality for 3D models, 2D drawings and Teamcenter attributes, workflows prior release.

Review external team work and test plans to assure requirements can be achieved.

Support the establishment of quality related training, best practice programs and techniques.

NTS Consulting, 2583 Chomedey Boul., Laval, QC, H7T 2R2, Canada

Quality Lead Design Engineer, Consultant

February 2014 / May 2014

NTS Project: Top Pylon Leap Assay Frame RSS and Mid Spar

Utilizing CATIA V5 software to check design, components, drawing generation, specifications and fined reliable solutions when problems occur.

Develop project schedules, documentation and present training on quality management processes, tools and methods.

Management Experience, internal/external team - Morocco.

Develop briefings on task plans, status and results, and provide briefings to team and company management.

Ensuring compliance with the relevant codes and standards engineering, and effective partnerships between internal/external teams.

Excellent ability to communicate effectively with all levels of the organization.

Initiate and support implementation and continuous improvement activities.

Lead projects designed to improve the efficiency and effectiveness of product quality & reduce cost.

Monitor engineering tasks to remain on schedule and within scope.

Process change requests and review controlled documents prior to release.

Protect the Intellectual Property rights of the Company. LEAN and 5S.

BOEING / COMFORCE, 13208 NE 20th Street, Suite 100, Bellevue, WA 98005, US

Structural & Payload Design Engineer, Consultant

October 2006 / November 2013

Boeing Programs: 747-8 Freighter, 747-8 Intercontinental, 767 FedEx & 777-300, Everett, WA, USA

Apply knowledge of engineering principles, customer requirements, vendor capabilities and requirements, company processes and design requirements, and applicable regulations (FAR’s, JAR’s) in order to create component and systems designs for use in the Cabin and /or Cargo Compartments of commercial aircraft, Commercial Airplane Airframe.

Met eligibility requirements for access to Export Administration Regulations (EAR) and Traffic in Arms Regulations (ITAR).

Apply knowledge of computer-aided design/analysis tools CATIA V4, CATIA V5, ENOVIA, IVT, PDM, READERS and ZERO ERROR in order to develop, integrate, and evaluate systems design and perform trade studies.

Apply knowledge of customer and certification requirements in order to ensure compliance.

Support of Airline, SAM and ITCM meetings and production.

Understanding customer design process, specifications, respect installation & maintenance requirements, schedules and ensure deliverables.

Participate in the design and control of major interfaces between, Manufacturing, Stress & Systems Engineering and Structural Suppliers Groups.

Experience in R&D of typical commercial aircraft (747, 767 & 777), primary & secondary fuselage structures, payloads, systems and layouts, participating in whole process of 3D Models & layout verification, workflow, control and release work packages in PDM & Enovia.

Experience with Boeing Conversions of Mechanical Systems.

Creating and modifying 3D Models, 2D Drawings & ECNs (Engineering Change Notice).

Expert for Aerospace Joggle and Flanged Hole Sheet Metal Brackets for primary and secondary structures.

Specifically worked on the systems designs of Intercostals, Fire Systems such as Fire Stops and Smoke Detectors, and Wing Fittings on 777-300 Program.

Linings and Walls on 747-8 Freighter & Intercontinental Program.

Ball Panel Installations, Beam - Clip Attachments, Floor Fitting Installations, Floor Panel Installations, Pallet Locks, Ribs, Rings and Shims on 767 FedEx.

Conveyer Systems Installations, Equipment Installation, Retractable Guide Rollers, Roller Trays, Side Guide Installations, Side Guide Support Installations on 767 FedEx.

Generates requirements and supports test for Flammability on 747-8 Intercontinental Program.

Centre Fuel Tank Installation on 747-8 Freighter - Auxiliary Power Unit (APU).

Power Drive Unit ‘PDU’ Systems Installations on 747-8 Freighter and 767 FedEx Program.

Power Drive Unit ‘PDU’ Drain & Tank Systems Installations – Tubing on 747-8 Freighter and 767 FedEx Program.

PDU Pans, Filters and Moisture Shroud Installation on 747-8 Freighter.

PCIP (Product Cost Improvement Project) - Investigate, develops and presents design reviews, FEM analysis, safety factor, design, improvements, and weight as well as cost and time reduction studies on PDU Ring Sizing, Electrical Bracket and connectors, 747-8 Freighter.

Water Waste - Tubing and Air Ducting Systems on 747-8 Freighter Program.

Worked on Investigation of Fastener Interfaces & Overlapping with Existing Locations.

Fasteners Interference with the Frame, Horizontal Splice(s), Floor Beam Collars.

Interference with Fasteners Installed on the Web of the Floor Beam. Shear Web Intercostal Interference.

Edge Margin & Clearance to the Edge of Shear Web Stiffeners on 777-300 program.

C&D AEROSPACE / ZODIAC / SAFRAN, 68, Boul., Brunswick, Montréal, QC, Canada

Mechanical Design Engineer, Permanent

December 2004 / October 2006

Bombardier Program: Global 5000

Utilizing CATIA V5 and Smart Team software to design business jet interiors.

Duties included understanding customer design specifications, respect requirements, schedules and ensure deliverables creating 3D solid modeling design and tubing for various monuments, creating associated 2D engineering drawings for those monuments.

Able to work under pressure on own initiative, and as part of a team, driving by results.

Conversions on 3D solid models from CATIA V4 to CATIA V5.

Expert with aerospace sheet metal brackets manufacturing and machining.

Produce ECNs (Engineering Change Notice) as required, providing technical support to customers, and stress as well as production department during manufacturing.

Specifically worked on the designs of aircraft interior products such as AFT & FWD Lavatories, Bulkheads, Dado & Composite Honeycomb Panels, Drainage Systems - Tubing, Floor Attachments and Latches for locking and mounting, Galley, Jigs for Curved Composite Honeycomb Panels (Tooling), Partitions, Shell Components and Walls used in commercial and private aircrafts.

EXCITING GLOBAL TECHNOLOGIES, St-Laurent, Montréal, QC, Canada

Lead Mechanical Design Engineer

Optical, Permanent October 2002 / October 2004

EGT Program: LED Continuous Lighting

Incorporate design improvements utilizing CATIA & SOLIDWORKS software with an emphasis on 3D Modeling, Drafting and Engineering Change Notice, as well as ANSYS & COSMOSWORKS for FEM Analysis for LED optical lighting products.

Demonstrated abilities to take a complete responsibility for design.

Guide Teams on project process, deliverables, developing, tracking, and reporting metrics; lead technical interchange meetings and/or working groups to resolve interfaces issues.

Lead selected engineering studies and coach less experienced engineers.

Optimizing optical design, acrylic surfaces on lens and mounting of commercial and industrial lighting.

Performed LED feasibility studies of Lamps, Reflectors, Signals, Corridor and Rail Lighting

Research and Development in Optics, Improving Safety, Visibility and Style.

Synchronized to Operate with Brake Lights (high intensity red color), Running Lights (low intensity red color), Turn Signals (amber color), and Hazards.

Testing of Brake Light, Bridge, Highway and Tunnel Continuous Lighting.

Management Experience of product designers and technicians. Support external supplier, China.

THORBURN EQUIPMENT Inc., Point Clare, Montréal, QC, Canada

General Machinist, Permanent

January 1996 / January 1998

Thorburn Program: Piping and Ducting Systems, Energy

Metallic and Non-Metallic Bellows Expansion Joints, Connectors for Piping and Ducting Systems, and Flexi-Duct Series Expansion Joints and Systems.

Petro-Chemical Loading / Unloading and Bulk Transfer Hose Assemblies and Custom Teflon Lined Conductive and Non-Conductive Hose Assembly.

Experience with Composite Materials (Fluropolymer Pipe Coated Fiberglass Fabric with Teflon Film Laminated to One Side).

Expert with manufacturing and machining sheet metal brackets, liners, flange joints and Ducting Systems.

Production-oriented with good leading skill to maintain high quality standard. LEAN experience.

Experience as General Machinist, jig & fixtures design, clamping device, sliding Jigs, drilling, punching, milling & lathe work.

EDUCATION

CONCORDIA UNIVERSITY, Montréal, QC, Canada

B. Engineering, Majoring in Mechanical Engineering Option: Design & Manufacturing

October 2002

CONCORDIA UNIVERSITY, Montréal, QC, Canada

Master in Aerospace, Option: Materials & Structures

January 2003 / 2004 - Independent

Courses Taken:

- Design using Composite Materials (Trailer Project, FEM - PC Laminates, CATIA & NASTRAN)

- Manufacturing of Composite Materials

- Materials for Aerospace

- Mechanical Behavior of Polymer Composite Materials

- Random Vibrations

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