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Engineer Engineering

Denver, CO
May 21, 2020

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Hesham Afifi

**** * ***** ******

Thornton, CO 80229 USA



Aerospace structural engineer with over 15 years of experience in aircraft design, analysis and operation. Possess a strong academic background and career record including a master of science in aerospace engineering.


Sierra Nevada Corporation Melbourne, FL

Aerospace Structural Engineer, Contract Sept 2018 – Present

• Analysis and design of NASA dream chaser cargo module

• Propose load path engineering solution and design changes to optimize design

• Participated in the generation of the Cargo Module finite element analysis model and verified it

• Substantiate vehicle’s secondary structure via finite element analysis to verity its strength

• Support and liaison with production to substantiate production issues and repairs during manufacturing

Craig Technologies – AAR Airlift Melbourne, FL

Aerospace Engineer, MRO March 2018 – Sept 2018

• Support the Department of State Bombardier dash 8 maintenance activities

• Substantiate metallic and composite repairs of aircraft

• Coordinate with multiple engineering teams to assess and analyze aircraft major and minor modifications

Northrop Grumman Corp. Melbourne, FL

Aircraft Structural Engineer April 2015 – Dec 2017

• Design and analysis of US naval aircraft E2D airborne early warning (AEW) o Analyzed trailing edge structural parts such as channels and joints. o Substantiated antenna’s structural support and its installation on the fuselage o Performed a finite element static and modal analyses of the aircraft parts using FEMAP/NX NASTRAN

• JSTARS Air force Program, MRO Support

o Evaluated structural repairs issued by production in support of the aircraft modification o Performed stress analysis of non-conforming repairs and ensured its structural integrity

Spirit Aero Systems Inc. Tulsa, Oklahoma

MRB Stress Engineer, Contract Aug 2014 – Feb2015

• Supported master schedule and delivery of Gulfstream, G650 wing o Validated by analysis structural repairs of rejected material, parts, and assemblies o Determined interface loads, joint stresses & margin of safety calculations o Executed structural analysis of alterations and modifications to the wing and its subassemblies

Embraer Engineering Technology Center Melbourne, Florida Product Structural Engineer May 2013 – Feb 2014

• Performed Stress analyses of aircraft secondary structures and interface with primary structure

• Worked with various teams to support aircraft delivery and issued required documentation for repairs

• Calculated stress concentration factors of new penetrations and evaluated its impact on fatigue life Gulfstream Aerospace Savannah, Georgia

Volt Engineering Services - Contract Stress Engineer Apr 2012 – May 2013

• Responsible for the stress sizing of Gulfstream aircraft wing stringers run-out analyses

• Utilized FORTRAN program to run FEA buckling, linear and nonlinear analyses of the run-out o Updated FORTRAN code with new material properties, configurations and confirmed results o Performed joint analyses of the run-out to upper and lower wing skins

• Conducted static analysis sizing on trailing edge cove panels O Analyzed the stability of the panels and their joints to upper and lower covers

Dassault Falcon Jet Little Rock, Arkansas

Stress Specialist Aug 2010 – Apr 2012

• Structurally substantiated aircraft interior components for abuse, emergency landing and ultimate loads

o Performed a finite element analysis on aircraft interior component using Elfini o Generated technical reports to validate integrity and installation of interior components o Recommended by analysis new methodology for cutouts substantiation in composite honeycomb panels

• Provided onsite technical support to mechanics during installation

• Performed and witnessed structural tests on inserts and honeycomb panels

Spirit Aero-Systems Inc. Wichita, Kansas

Structural Analysis Engineer Jan 2009 – Aug 2010

• Development and Design of A350XWB composite wing spar o Responsible for the stress sizing calculations and optimization of the wing front spar o Conducted finite element, buckling, unfolding and damage tolerance analyses of spar section

o Performed mass studies and identified weight savings opportunities o Coordinated with design team to identify composite lay-ups & minimum required thicknesses

• Liaison between engineering and customer for product tool development o Assisted with debugging stress software tool for discrepancies and suggested improvements

• Represented stress engineering team in configuration management activities

JetBlue Airways, LiveTV Orlando, Florida

Aircraft MRO Structural Engineer Aug 2004–Jan 2009

• Contributed in design reviews & manufacturing implementations of in-flight entertainment system o Participated in new rack mounting design and interior configuration modification on B737-900, A320

o Substantiated fuselage structural modification due to wireless antenna installation

• Performed hand calculations during aircraft structural repairs and worked with DER to assure their integrity

• Enhanced product quality to meet customer satisfaction and controlled production cost o Developed rack test equipment and reduced the continuity test time from 12 to 0.5 man-hours per rack

• Supported manufacturing operations and streamlined part manufacturing approval process EDUCATION

Embry-Riddle Aeronautical University, Daytona Beach, FLUSA Master of Science in Aerospace Engineering, Dec 2009

“Analytical Approach in Approximating the Steady State Response of Structures”, CGPA 3.6/4.0 Bachelor of Science in Aircraft Engineering Technology, Dec 2003 PROJECT EXPERIENCE

Thesis Topic:

Utilized the combined approximations methods for efficient approximation and reanalysis of structures, reducing the number of degrees of freedom in a dynamic system by 90-95% with high quality results Clearance and TRAINING/SKILLS:

• DoD Secret Clearance, Date: May 31st 2016

• IPC/WHMA-620, ASTM, and RTCA/DO-160 Environmental testing, Familiarity with FAR part 21, 25, and 145


“A Combined Approximation Based MATLAB Code for Dynamic Re-Analysis of Aerospace Structures”. Conference Proceedings of Congress and Exposition ASME International, November 2009.

“An Efficient Dynamic Re-Analysis of Aerospace Structures Using Combined Approximation Technique”. 51st AIAA/ASM/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, April 2010.

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