Dear Hiring Manager,
I am interested in the Mechanical Design Engineer position.
I have extensive experience, over 25 years, in Mechanical Designer. I have worked with Pro-E (CREO), SolidWorks, NX and AutoCAD. Throughout my career, I have taken ideas from a conceptual stage to prototyping to testing to manufacturing & launch. I am able to work in a quick project turnaround environment. My career path has given me the ability to work with all levels and across all departments to accomplish project tasks and meet milestone schedule points.
Verification Testing: Testing Designs to insure that the requirements for the prototypes are validated. Writing the design outcome for engineering review for the FDA reporting.
Drawing: Worked with red lines, ECO’s, and BOM’s to complete all drawing packages for engineering, quality, and manufacturing review and release. Professional working relationship with vendors to insure that all information is accurately communicated.
Materials: Aluminum Extrusions, Lower Volume Metal stamping, Hydro forming sheet metal, Plastic Injection molding, wiring diagrams, circuit boards, heat shrink coating, and extrusions. carbon fiber.
Reverse Engineering: I have many years’ experience of “reverse engineering” on existing part or assembly.
Quality: I have implemented quality plans working with SPC to identify issues and resolve problems. Developed and implemented process control plans for testing and inspection. I am able to read and use measuring equipment such as calipers, micrometers, and optical comparators to name a few.
Project Lead: Led teams for projects such as RF Cool Tip, Microwave, Temperature probe.
Voice of the Customer: Listened to physicians and nurses to gather information on product improvements. Prototyping new devices, and packaging per requests.
42 Patents: I currently hold 42 Patents consisting of Medical devices, Automotive, and Consumer products.
Black Belt: Achieved in 2006 when employed with Sunbeam working on the Humidifier Project that was based on a recalled issue.
With my multiple years of experience on various software programs and working with a diverse group of individuals, I feel I would be a great asset to your team. I appreciate your time reviewing my qualifications and I’m looking forward to interviewing with you for the Mechanical Design Engineer position.
Arnold V. DeCarlo
(C): 303-***-**** / Frederick, CO
Mechanical Design Engineer
Project Lead on multiple projects for RF Cool Tip, Microwave and Temperature probes. I had several technicians and designers reporting to me. Extensive experience performing 3D CAD design, and organizing documentation for improved manufacturability of custom medical products. Successful in creating documents for manufacturing and testing equipment, validation documents, reports, and writing statements of work for the purchase of manufacturing and test equipment. Recognized for taking a customer-focused approach and working across all levels of an organization to meet milestone schedule points, and drive projects to completion. Currently hold 42 Patents consisting of Medical Devices, Automotive and Consumer products.
3D Modeling / Solidworks, NX/ Pro/E CREO
Plastic injection molding
Failure Analysis on components
Prototype Engineering RF/Microwave systems
Intralink / Windchill
Agile Software engineering files ECO’s & BOM’s
Stress Analysis Software
FDA Design Controls
GD&T & Stacks ANSI/ASME Y14.5M
Six Sigma Black Belt
CAPA / 5 Whys
Metal stamping/ Metal casting, Welding, Cardon fiber
KIOSK Louisville, CO
Mechanical Design Engineer September 2016 to January 2019.
Collaborated with project managers on product for new custom orders, and worked with DFM on product assembly development for the prototype. Experience with sheet metal parts, plastic injection parts. Managed new project requirements from inception to release for low volume manufacturing. Created Drawing for manufacturing and tooling for production designs. Responsible for creating ECO’s and BOM’s. Updated results on testing reports.
Work with Sale, and project Managers on the time line on projects. Cost saving of 22% before committing to low volume tooling by reducing part count and weight savings.
Launched a $2.4 million project on time. Worked with DFM for the design of assembly and approval of the manufacturing. Cost saving of 15% on the manufacturing line.
Collaborated with manufacturing in design of assembly fixtures for ease of assembly.
U.Q.M Technologies Longmont, CO
Mechanical Design Engineer Contract Work May 2016 to September 2016
Working on DOE electric motor design tooling to improve motor performance. Working with manufacturing so tooling design meets requirements for assembly procedures. Researching new materials such as carbon fiber wraps for better strength of rotor assembly. Collaboration with team members such as Manufacturing Engineers, Management, and Marketing on final product design. Responsible for creating ECO’s and BOM’s. Continually updating drawing and results on testing reports.
Analysis to determine why carbon fiber failed to stay on rotor. After investigation discovered that the consistency of adhesive applied to the carbon fiber during manual operation was inadequate for application to the rotor.
Consulted with vendor to have the adhesive applied to carbon fiber to control consistency of adhesive. This will eliminate the manual operation of applying adhesive to the carbon fiber in
Water jetted parts for Olympus X-ray chamber for customer approval. Cost saving of 35% before committing to low volume tooling.
Worked with DFM for the design of assembly and approval of the manufacturing and lean team.
Collaborated with manufacturing in design of assembly fixtures for ease of assembly.
Hunter Douglas Broomfield, CO
Components Engineer February 2015 - January 2016
Designed products ranging from new window coverings to test fixtures. Resolved manufacturing modification delay issues prior to production. Collaborated with customer engineering design teams on product development for manufacturability. Coordinated with customers and vendors on resolving quality challenges.
Developed and managed three projects: Power view, Simple Motor, and LiteRise. Completed design, drawing, and tooling for DFM (design for manufacturing).
Created time savings of 30% by utilizing existing parts and making some modifications to product.
Worked with cross-functional teams on product development and vendors.
Developed prototypes so the management team could make decision to release product on time.
Info Tree Louisville, CO
(Medtronic) Contract work August 2014 – February 2015
Designing medical products ranging from Spine Clamps to Tracking Frames, product development for TCA Robot, and working on the New Medical Cart Project. Resolve manufacturing modification delay issues prior to production. Collaboration with customer engineering design teams on product development for manufacturability. Coordinate with customers and vendors on resolving quality challenges.
Project Lead in Resolving Root Cause Analysis to eliminate defined problem. Customer complaint that the frame was disengaging on product. After investigation discovered that the spring was modified without authorization. Worked with vender to correct this issue.
Worked on the Cart Project designing new Arm Handles and IO panels. Marketing presented to management for there approval to keep the project on time for product launch.
Work with cross-functional teams on product development for TCA Robot. Worked with the ECOs so team can release product on time.
COVIDIEN (formerly known as ValleyLab), Boulder, CO
Medical Devices – Domestic and International (2005-2013)
Designed medical products for Oncology division ranging from Catheters, Temperature Probes, Cool Tip RF for liver ablation, and Microwave for lung ablation. Partnered with cross-functional teams on product development for Vessel Sealing Devices and Surgical Pencil. Explained design analysis decisions and relayed layout drawing information changes to Vehicle Design team. Resolved all manufacturing modification delay issues prior to production roll out. Collaborated with customer engineering design teams on product development for manufacturability. Managed new project tool requirements from inception to release for volume manufacturing. Coordinated with customers and vendors on resolving quality challenges.
Project Lead for the product design for Cool Tip RF due to quality issues by researching high-energy microwave systems and RF design and leading product redesign. New product design removed quality issues, reduced labor costs by a head count of 3 on the production line, and largely increased profitability for each unit. Initial Rate of Return (5yr) 289%. Cost saving of $2.53 mil. Became most profitable product in company history.
Designed plastic injection molded parts, metal stamping, wire routing complete with drawings and GDT for product launch in Pro/E CREO for high volume product
Tested and wrote reports for design validation for product launch to be in compliance with FDA and conducted stress analysis for various new products in Pro/E CREO to maximize material cost.
Performed product development for RF and Microwave antennas to increase ablation size and efficiency.
Streamlined manufacturing line using LEAN principles which reduced costs for multiple projects by working with FMEA to assign high-, medium-, and low risks of failure in order to minimize risks.
Maintained/achieved on time delivery for Cool Tip project parts by managing vendors and suppliers.
Reverse-engineered existing parts though product investigation and validation on energy return pads.
Valley Lab Inc. (now known as Covidien), Boulder, CO
Contract Senior Designer,
Medical Devices – Domestic and International (2004-2005)
Brought in on contract basis before becoming permanent employee to set up and validate new Market OEM medical production work cell. Delivered on time Project Milestone objective with positive results. Managed multiple redesign, rework, and validation for improved performance and reliability of work cell equipment. Completed the restructuring of a 3D CAD design of prototype equipment for repeat manufacturability. Created structure Bill of Materials for purchasing and tracking components cost.
Project Lead for the temperature probe from voice of the customer report. Product was developed by gathering information from the physicians for new product launch.
Team member in designing the Electrical/Surgical 3-Button Pencil.
Designed the exterior handle for the RF Cool Tip and verified on Stress analysis Software.
Assisted the design group on the testing and modifications of the RF Cool Tip.
Project Lead on cost savings and reliability to improve the RF Cool Tip product.
Worked on various projects: Introducer, Argon Gas, testing fixtures, and electrical/surgical needle cover.
Communicated with vendors for tooling costs and prototypes. Management of outside vendors delivery of goods and services worth $250k
U.S. DEPARTMENT OF ENERGY, Battelle Labs (DOE)
Mechanical Design Engineer
Spallation Neutron Source Project (2000-2003)
Collaborated with customer engineering design teams on product development for manufacturability. Managed new project tool requirements from inception to release for volume manufacturing coordinated with customers and vendors on resolving quality challenges. Used Pro/e 3D CAD to create supplemental manufacturing support drawing and production design Management duties include ECO’s and BOM’s.
Project Lead for the equipment vacuumed lines, power delivery systems, and piping with regulatory system and monitoring, pressure vessels with-high powered laser.
Communicated with physicists on design requirements for industrial safety on the beam line of large assemblies as magnets, laser beam equipment and architecture layouts.
Tested and documented prototype for fit and function before final production.
Integrated electrical & plumbing in designing systems for safety with written reports to management on corrective actions.
Obtained security clearance.
Designed and implemented safety systems remote clamp for the beam windows and many parts and
functions for the beam line. Have worked with radioactive and hazardous materials.
Created and implemented report to management on safety in the working team for OSHA standards.
Responded to requests from workers identifying risk in the work environment. Established corrective actions and reported to team and management.
ADDITIONAL RELATED EXPERIENCE
Sunbeam Health at Home, Aurora, IL
Kolcraft Enterprises, Chicago, IL
ITW Deltar (Automotive Division), Frankfort, IL
Product Designer, Quality Engineer, Layout Lab Tech, Quality Control Inspector
Joliet Junior College, Joliet, IL
Field of Study: Design Engineering
Certificate of Completion GDT Applications & Stacks
Mechanica, Wildfire, Pro/E Intralink, Six Sigma black belt training, Pro-Surface Advanced training, Advance Part Design, Pro-E Basic Manufacturing, Pro-E Users Group, Designer Guide to Part Design, Geometric Tolerance, Statistical Methods Workshop
Currently hold 42 Patents consisting of Medical devices, Automotive, and Consumer products.
Former member of Society of Plastics Engineers
Creative Problem Solver, Designing RF/ Microwave antennas, Design for Manufacturing and Assembly (DFMA), Injection Molded Plastic Part Design, Industrial Design, Human Factors/Usability, Sheet-metal Part Design, Prototyping/Rapid Prototyping, Additive Manufacturing, Test Fixture Design, Pro/Engineer Wildfire & Creo, Pro/Engineer Advanced Surfacing, Pro/Engineer Sheet-metal, Windchill/PDMLink