Mechanical Engineer Design

William L. Coffey, PE, MBA

**.******@*****.***

www.linkedin.com/in/williamlcoffey 831-***-****

Professional Summary

Senior Engineer supporting product design and manufacturing. Support subcontract component manufacturing, and tooling to assemble components for medical devices, antenna test support, scientific instruments, semiconductor components, ion lasers, condensers, x-ray tubes, airbags and defense products. Support project, manufacturing and design engineering tasks. Proficient with CAD modeling using Solidworks and Pro E. Experience with the following:

Brazing and diffusion bonded high vacuum assemblies. Aluminum brazing

Vacuum components and subsystems

Design / manufacturing of glass to metal seals

Electromagnets

Hydraulic, Pneumatic System Design

Propulsion Gears

Machined components & Sheetmetal

ASME pressure vessels and power piping

Tooling design

Welded Structures

Knowledgeable in material selection

Manufacturing of ion lasers and x-ray tubes

Energetic assemblies

Plastic injection over molded metal assemblies

Optic mounting

Operate PLC equipment

Lab view GUI interface and data acquisition equipment

Select sensors and instrumentation for signal conditioning systems for data acquisition

Analysis Tools: FEA Simulation and analysis

Key Accomplishment

Technology Management services developing supply chain for mil aluminized steel through aluminum brazing project.

Project and Program Management certificate UCSC 3/2013.

Implemented new industrial cutting edge digital x-ray inspection method to screen for artifact free beryllium windows used in mammogram windows for medical industry.

Designed K63 Quick Clamp design to meet the production utilization for operator handling of high temperature assembly/disassembly semiconductor operations.

Responsible design engineer delivering to US Navy two Trident 2, D5 test vehicles permitting Westinghouse to receive $1M award fee for first launch delivery. Supported the design and stamped drawings and stress calculations for D5 vehicle as a pressure vessel. Manufacturing engineer for CG63-CG69 reduction gears sets for US Navy.

Professional Experience

Natus Medical, Sr. Mechanical Engineer Pleasanton, Ca (R&D Partners subcontractor) 10/19 to 2/2020

Supported RetCam Retinopathy of Prematurity (ROP) NPI competing design, detailed drawings for a mold tool toed support fiber optic cables. Support mounts around conical optic lens to provide desired illumination path. Created using Solid Works 2017-2018. Engaged with Natus staff and other in-house subcontractors. Provided 3D printing of 2x scale model in support of proof-of-concept mold tool. Wrote Optic Bonding Ageing Thermal Humidity Life Test Verification Protocol. Work with compliance engineer. Performed thermal and humidity acceleration factor (AF) reliability life testing calculations. Contacted adhesive suppliers obtaining adhesive operating temperature limits data not in published documents. Completed QMS training.

Coffey Engineering, Design Services San Jose, Ca. 6/17 to 10/19

Marketing: Submitted proposals for design upgrade projects to Amazon local; a Ramp Widening Project and a Bumper Guard Protection design. Kept abreast attending Comsol Release 5.3 and Analysis workshops, San Jose, Ca. 11-2018. Attended 5 G telecommunications Design Conn Santa Clara 1-2019

Fresenius Medical, Sr. Mechanical Engineer (Oxford International Subcontract Concord, Ca. 10/16-5/17

Kidney Dialysis Machine NPI for sheetmetal and labels for Bluestar machine. Labels per IEC 60601- 2012. Re-designed and fabricated four production sheet metal components using Solid works 2014. Created 4 mylar color labels and released to production with sheet metal and label suppliers. Conducted design reviews with cross-functional team including United Labs. Performed reliability accelerated (AF) life testing calculations. Wrote test protocol for chemical wiping labels and panels for durability testing in accelerated environmental temperature chamber. Test evaluated legibility and bonding of labels to plastic cabinet for equipment 7 year life.

Wrote Engineering Test Reports evaluating polypropylene material grade substitutions for product handles and 10 Liter container. Provided project schedule in Microsoft projects.

KLA TENCOR (Oxford International Subcontract Mechanical Engineer) Milpitas, Ca. 6/2016-8/2016

Design NPI Surfscan7 Rotary Frame Tool using 80-20 members and machined components to rotate 500 lb. assembly to provide manufacturing support. Provided design reviews. Used Solidworks 2014 released into EPDM.

Dunan Sensing, Sr. Manufacturing Development Engineer, San Jose, Ca. 3/2016-6/2016

Responsible for NPI “Button Gen1”pressure sensor MEM fabrication using eutectic brazing, wire bonding, soldering ceramic bonding with adhesives in production environment. Operated process equipment to perform MEM electrical interconnections and assembly.

Designed and subcontract manufactured assembly tooling of ceramic, and graphite materials using Solid works 2015. Performed final assembly electrical and pressure acceptance testing using data acquisition station. Created manufacturing methods. Released production cost report to management. Developed new graphite supplier source to increase capacity. Supplier provided an improved machinable high temperature graphite for the braze ceramic to MEM eutectic joint process for next generation ceramic pressure sensor.

PCB design with high capacity end connector. Performed sterilization cleaning and bakeout.

Oxford International Subcontractor at Altex Technologies, Mechanical Engineer, Sunnyvale, Ca.12/14-10/2015

Design and develop manufacturing process for DOE Dry Cooling project, an aluminized steel to aluminum liquid to air condenser design using high temperature brazing process. Provide technology support of supply chain from mill to secondary sourcing, sheet metal, welding subcontractors and braze development. Designed final geometry and heat exchanger manifold using solidworks 2013-14. Performed calculations as required.

Cobham Sea Tel, Concord Ca. Mechanical Engineer, Walnut Creek, Ca. 6/2014-10/9/2014

Subcontract Mechanical Engineer providing design and design reviews for Tilt-Translate Antenna Weldment Table using Solidworks 2013. Obtained cost to manufacture 4 configurations in trade-off cost vs function comparison. Developed 2 drive systems Jack Screw and ACME Drive both using Rail and Guides for translation mechanism.

Supported RF TRVO project group with two designs with fabrication for Ka, Ku Adapter and OMT Interface Range Adapter.

Coffey Engineering, 2012 – 6/2014

Provide machine design subcontract services. Approved vendor list for Samina Corporation.

Materion Electrofusion, Fremont Ca. Project Engineer Fremont Ca. 10/2010-8/ 2012

Wrote next generation company standard IS-50M-AF Artifact Free Beryllium Specification principally used in the medial industry. Established industry standards implementing ASTM E1742 to inspect beryllium. Developed from radiographic digital inspection research. Created test conditions and measurement standards to identify artifact and calculate size. Wrote testing procedure. Trained inspector. Demonstrated technique to Materion and Customer staff. Established engineering procedure to inspect beryllium window with state-of-the-art digital x-ray equipment. Represented engineering as a key team member along with Sales, Marketing and Development group to work with customers to upgrade in-house inspection.

Developed the design, created manufacturing release to delivery of beryllium (Be) customer special window assemblies. Windows are used in commercial x-ray instruments, national and international synchrotron facilities and other scientific instruments. Performed high vacuum differential pressure testing acceptance testing reporting results. Interfaced with principal scientist obtaining customer approval for the design of high vacuum window assemblies and vacuum vessel to test windows assemblies using Solidworks 2010.

Conducted DOE on diffusion bonding process that reduced scrap for 3 Varian product families improving yields from 70% to 95%. Applied Minitab DOE analysis to establish operating processes. Performed equipment Installation Qualification (IQ) testing and performance operations. Performance Qualification (OQ) testing to yield control plan settings in performance qualifications (PQ).

LifeSparc Inc., Hollister Ca. Project Engineer/Manager, Hollister Ca. 10/2005-8/2009

Project manager of a cross functional team that developed high volume automotive airbag initiators.

Implemented automotive industry FMEA and DFMEA procedures for GTMS design changes and NPI Stage 2 initiators. Conduct design reviews for new processes. Prepared and managed capital expenditure budget.

Project Engineer building customer R&D initiators per USCAR28, thermal shock and temperature/humidity aging duration tests requirements. Performed data analysis on lot acceptance reporting statistical critical performance parameters.

Provided kaizan engineering support to by optimizing production resistance weld settings based on results of DOE study. Performed bridgewire pull test, SEM weld visual inspection presented test reports.

Championed PPAP (Production Parts Approval Process) to qualify Sylvania Tungsten using DOE analysis. Applied anova hypothesis testing to reduce final electrical test TTT rejection rates to less than 2%. Presented test reports.

Submitted PPAP for supplier recommended GTMS geometry changes with no impact on the component function and their manufacturing on the high-volume automated equipment, maintaining automated equipment 1.33 Cpk.

Designed and released into production a 1-ohm inert powder and slug configuration blue body injected molded initiator using Solidworks 2009.

Created R&D tooling: Radius Electrode Tool, Pin Straightener, Horizon Blade Removal Tool and others tools.

Interfaced with world class glass to metal seal (GTMS) manufactures performing process audits of Indept Safety Systems Vesitin, Schott GTMS, Lanscron Czech Republic, and Electrovac GTMS facility in Selswig Germany.

Oxford X-Ray Technology, Scotts Valley, Ca. Manufacturing Support Engineer Scotts Valley, Ca.1/2005-10/2005

Designed RF vacuum braze tooling and lead shield alignment station to increase production rates.

Manufacturing engineer supporting X-ray tube manufacturing of bone density diagnostic equipment.

Released new micro focus Anova x-ray gun manufacturing assembly methods and trained operator.

Pacific Scientific, Hollister, Ca. Manufacturing Engineer, Hollister Ca. 6/2002-11/2004

Responsible for lean manufacturing (Toyota Production System) implementation of high-volume assembly of bridge wire initiated energetic devices. Trained and implemented Value Stream Mapping, Standard Work, One Piece Flow quality programs into manufacturing builds to reduce waste. Performed lot acceptance testing, and 100%x-ray inspection. Release ISO 9002 manufacturing assembly methods.

Upgraded pneumatic loading station to autoloader increasing production capacity 5 times to meet production demand, using Pro-E. Designed hand loading tooling for product.

Coherent Laser Division, Santa Clara, Ca. Sr. Manufacturing Process Engineer, Santa Clara, Ca. 6/1999-5/2002

Responsible for manufacturing all braze assemblies in WJ belt furnace and two Hetherington Hydrogen Bell Jar furnaces as well as other process equipment for the division.

Managed four high vacuum brazing active braze alloy to ceramic stations. Managed four vacuum bake-out burn- in and inert gas fill stations operations for optic windowing.

Supported cathode activation runs and thermal measurements. Performed optical pyrometer temperature and emissivity corrections measurements in high temperature and vacuum environments.

Supported new product introduction for Model 308 and 322 Lasers.

Provided ECO manufacturing signoff. Performed failure test inspection to determine root cause.

Supported production for ion lasers with goal of 90% first pass yields.

Designed assembly station tools and documented existing tools Pro-E.

Other Experiences

Westinghouse Electric (WEC) Marine Division, (Northrup Grumman), Sunnyvale, Ca.

Watkins Johnson Semiconductor, Scotts Valley Ca.

Premier Microwave, Santa Clara, Ca., Magnetics Engineer Santa Clara Ca.

Computer modeled magnetic field shape using legacy Gamma program for two new products. Manufactured GW8614, GW8616 Electromagnets. Delivered to customer.

Manufactured and tested water- and air-cooled wire and foil style electromagnets.

Modified cooling plate design to reduce pressure drop.

Upgraded braze tooling to manufacture 6 stacked units per braze load using graphite insulating plates.

Brazed waveguide cooling passageways and mounted ferrite for passive devices.

Education

Project & Program Management (PMP) Certificate, UCSC-Extension Santa Clara, Ca. March 2013

MBA University of Phoenix, Technology Management, 2006 Santa Clara, CA.

BS Mechanical Engineering, San Jose State University, San Jose, CA.

Registered Professional Engineer, State of California, No 17599

Post Graduate Studies Mechanical Engineering San Jose State University, San Jose, CA.

Dynamics, Vibrations, Automated Controls, Heat Transfer, Microelectronic Packaging, Mathematics, Modern Physics, Semiconductor Processing, Electronic Optical and Magnetic Property of Materials, C Programming.

Computer Skills: Solid Works, Pro-E, AutoCAD, Lab View, C, Magnetics, Nastran, Mathcad

Software: MS Office Suite

Certificate of Completion: Access 2020 Database workshop, Intermediate-Advance Excel 2020

MS Projects, Minitab, Adobe Professional

Database: SAP, Pointman, Agile, Intuitive, Access, Oracle, Vantive, 4D, Brio, AS400

Training: FDA Process Validation Requirements and Industry Practice Certification 2012

TCT Trans catheter Cardiovascular Therapeutics Conference San Francisco, September 2009.

Geometric Dimensioning and Tolerance Training Classes 5/2012 - Bill Tandler, Instructor.

COMSOL Multiphysics free Training and Software utilization seminars 2018

Rhodes Schwarz Fundamentals RF Design Series May -June 2020 seminar

Solidworks Design for Manufacturing Digital Conference Oct 6-8, 2020

Contact this candidate