Chief Mechanical Systems Engineer

Bill Birgen 480-***-****

SUMMARY OF SKILLS: ** years as systems and component engineer and project manager. 20 years of D0-160/Mil-810 testing/certification, 20,000 hours NX/UG; 6,000 hours Teamcenter, 4,000 hours Catia, 1,000 hours Coolit (CFD); 2,000 hours Flowmaster (CFD); 1,000 hours MATLAB; Developed systems/devices for the following chapters: ATA 21, 25, 30, 35, 36, 38, 49 & ATA 75. Patent holder.

EMPLOYMENT HISTORY:

6/2020 to present SAVRpak Tempe, AZ

CTO: Oversees the development and dissemination of technology for external customers, vendors, and other clients to help improve and increase business. Authored 12 patents, and managed final approval of patents with legal team and USPTO. Managed certification of products with USFDA. Won the X-Prize Next Gen Mask Challenge. Won UN Sustainable AgTech Challenge. Inventions won Time Magazine’s Best Invention of 2021. Inventions also published in Wired Magazine. Invented convection-based inertia water separator. Invented active moisture removal system leveraging the dewpoint to extend shelf life of produce over 100%.

10/2016 to 6/2020 Honeywell Tempe, AZ

BLEED-AIR ECS SOFTWARE/ CONTROLS ENGINEER: Authored Electronic Signal Definition Spec report, defining B-21 aircraft ECS electronic, digital and non-digital signal interfaces and connectors for 1552 & CAN bus messages and conversion. Developed and integration of ECS/bleed air/pneumatic ASCU controller, ECS FMEA, and lab simulation of system. Performed heat transfer mapping of next gen Predator Drone engine combustor. Develop iron bird test facilities, and test procedures. Develop APU dust ingestion research and development test equipment.

IoT SYSTEMS ENGINEER: Created process for interrogating CAN Bus data both FMS and proprietary signals and transmission of said data via 2G, 3G and 4G networks. Integrated GPS geo-fencing and operator identification and authorization hardware on said international GSE (ground support equipment).

1/2015 to 1/2017 Kyllburg Technologies LLC Tempe, AZ

CTO: Developed and tested new super-cavitating munitions, ignition and delivery systems.

Authored patents for various emerging technologies in IoT consumer electronics, food packaging, and precious gem industries.

1/2016 to 5/2016 BAE Systems Mojave, CA PRINCIPAL MECHANICAL SYSTEMS ENGINEER: Managed technical solution, schedule and budget for mechanical systems on Stratolaunch Aircraft. Performed ELOS (equivalent level of safety), FMEA and reliability analyses. Authored CPCS proposal for twin fuselage Stratolaunch aircraft. Through analysis, identified Min-K insulation requirements for titanium pneumatic manifolds. Create/specify requirements and identify supplier sourcing for Stratolaunch Aircraft, CPCS, ECS, Pneumatics, Hydraulics, APU, Rocket Fuel, Fire Detection/Suppression & Pressurization. Calculate maximum allowable leak rates per FAR 25 on schedule and on budget. Created systems' architecture, failure mode analyses, pressure drop, sonic flow limits, thermal expansion and air flow heat transfer analyses, insulation requirements, as well as qualification requirements. Verified via hand calcs/ Excell reliability predictions calculated via Relex software. Determined DO-160 and FAR 25 ELOS through analysis. Create verification plan, test plan and test procedures and establish exemptions and conformities with FAA requirements as well as manage DERs. Design ECS per new FAR regs for commercial space tourism/travel. Present system status at PDR and CDR. Initiate cost saving studies, establish BOEs & contract deliverables, managed design team, interface/coordinate with manufacturing department for planning reqs. Coordinated with manufacturing for modification and salvaging of 747-400 cabin pressurization hardware in accordance with FAR 145. Wrote smoke clearing test plan and procedures for verification of (cabin pressurization) outflow valves. Specified cabin pressurization monitoring hardware and indication system. Stratolaunch Aircraft has an unoccupied, pressurized cabin, creating unique challenges for cabin pressure monitoring. Specified eutectic salt fire detection system and test verification method. Created specifications and sourced Halon fire extinguishing system for engines and APU. Specified eutectic salt and bi-metallic fire detection systems and installations. Worked with DERs for development of acceptable test plans. Managed and analyzed ARINC-429 label verification via bench and aircraft level testing. Conduct ELOS, FMEA, zonal & causality, fault tree reliability analysis.

2/2014 to 1/2016 Honeywell Phoenix, AZ PRINCIPAL SYSTEMS ENGINEER: Wrote DO-160 qual reports for A350 supplemental cooling R134a VCS palletized system. Performed V&V of RF (radiated and conducted) ASCII DO160 test data.

2/2012 to 12/2013 BAE Systems Mojave, CA MECHANICAL SYSTEMS PRINCIPAL ENGINEER: See BAE Systems above.

10/2011 to 2/2012 Bombardier Montreal, QC SENIOR PROJECT ENGINEER: On GX-7000/ -8000 Authored Humidification Systems Requirement Document. Initiated heat exchanger weight savings proposal. Developed and presented avionics cooling and fire suppression system, method, architecture of pressurized cargo and avionics compartments with schedule, performance and cost factors always present. Exercised weight saving design changes to primary heat exchanger. Managed Liebherr and Arrowhead suppliers and their on-site and off-site resources. Identified DO-178 requirement levels of systems’ and Transport Canada and FAA test plans while working with agents of each organization.

1/2010 to 10/2011 Honda Jet Greensboro, NC PRINCIPAL PROJECT ENGINEER: Specified eutectic salt fire detection installation DO-160 qual test plan, procedure and performance verification testing. Wrote pressurization system requirements document and qual/certification test plans and procedures. Perform certification test witnessing duties. Monitored live telemetry data and relayed CAS messages to flight control room during flight testing. Provided live on demand diagnoses of mechanical systems during in flight warnings, based on streaming telemetry data. Wrote bleed air system requirements document. Conducted aircraft bleed air system and pressurization system, development testing on aircraft. Managed system and system component suppliers and delivery schedules. Wrote, witnessed, conducted software regression testing of ARINC429 control (and discrete signals) of bleed air system, overheat detection, pressurization and avionics systems and integration. Wrote, witnessed, conducted, bleed air system functional and leak tests. Designed all required test equipment. Developed mods to aircraft VCS condensation draining. Identified FAR 25 requirements, DO-160 test levels as well. Worked with multiple DER for final approval of certification plans of systems and components.

2/2009 to 1/2010 BAE Systems Mojave, CA PRINCIPAL SYSTEMS ENGINEER: See BAE Systems above.

1/2004 to 2/2009 SEAMECH International Houston, TX

VP ENGINEERING: Managed team of DERs for purposes of certifying ECS systems for multiple customers. Managed the development of bleed air systems and components for Embraer, Cessna, Honda, Eclipse, Cirrus, Diamond, Columbia, Piper, Bombardier, Mooney, ATG, & Quest. Wrote DO-160 and DO-178, FAA compliance matricies, certification plans and test procedures. Witnessed as DER designee certification/ qual testing and wrote certification/ qual reports. Conducted reliability studies of entire ECS, VCS and pneumatic systems, predicting MTBFs. Designed wind tunnel for verifying pylon heat exchanger flow performance, and conducted said wind tunnel performance verification testing. Conducted flow analysis and testing of cabin air distribution (ECS) for various private aircraft designs. Conducted buoyancy analyses for sump drain seals and their effectiveness at various cabin pressure vs. altitude pressures. Developed ECS solutions comprised of custom bleed air composite valves utilizing PWM & stepper motor actuators/controllers. Sized high temperature stainless heat exchangers and ram air flow inlets. Developed 6 HP 28VDC compressor drive motor technology/supplier. Interfaced with customers (domestic & international) to determine technical expectations of electro-mechanical aircraft bleed systems including touch screen cockpit interfaces. Developed cost, power & weight constraints as well as delivery, test & qualification schedules. Prepare FAA test plans, procedures and qual reports on behalf of customers. Coordinate qualification testing resources including the outsourcing of testing. Managed a design staff & meet with domestic & international manufacturing resources and customers. Managed Material Review Board (MRB). Create design standards & process manuals. Managed software/hardware team to develop ECU EMI requirements as well as GUI and maintenance access of error codes for diagnostic purposes. Created composite fab company to meet outsourcing needs of high temp, EMI shielded composite components/structures utilizing RTM & hand layup processes. Developed steriolith tooling fabrication process as solution to kaizen study.

9/2003 to 5/2004 HONEYWELL AEROSPACE Tempe, AZ SENIOR MECHANICAL ENGINEER: Managed the development of a collection of oxygen system valves and bleed air valves for the JSF program. Wrote 2nd and 3rd mile stone status reports for responsible hardware. Managed reliability studies of valves’ assemblies predicting MTBFs. Outsourced design and engineering support to support schedule and cost targets. Managed, witnessed, documented MIL-STD-810 development testing of F35 engine bleed air valves any oxygen system valves. Created test reports and interfaced with customer and other business units. Organized and directed off site salt fog testing and on site 3rd shift vibration testing.

3/2003 to 9/2003 B/E Aerospace Winston Salem, NC INTERIORS ENGINEER SENIOR: Create & analyze first class seating designs with integrated pneumatic and electromechanically activated adjustments and integrated entertainment systems, including user controls interface.

4/2002 to 3/2003 ITT GILFILLAN Van Nuys, CA ELECTRO-MECHANICAL/THERMAL/FLUID SYSTEMS ENGINEER SENIOR: Create & analyze CFD models of electronics & power systems utilizing Coolit software. Calculate thermal inequalities between an ethylene-glycol/water mix vs. water, for the SPS-48E cooling system. The cooling system contains 5 cold plates & 2 air/liquid heat exchangers (HX). Compute HX film coefficients. Solving thermal inequalities by quantifying the required flow increase of the ethylene-glycol mix & augmenting mix with a copper oxide nanofluid. Perform lightning rod wind load calculations for the MACS ASR.

7/2001 to 4/2002 Northrop Grumman Baltimore, MD MECHANICAL RF ENGINEER SENIOR: Designed & packaged active IFF antenna manifolds for Wedgetail program, including eleven layer "via" IFF manifolds. Designed & integrated an isogrid ground plane into the IFF antenna to meet random vibration requirements. Performed weight saving & cost reduction initiatives. Evaluated cooling requirements for resistors & transformers. Utilized steriolithography for rapid prototyping of various antenna structures & secondary aircraft structures. Performed Laser Doppler velocimeter vibration testing & analyze the results.

11/2000 to 7/2001 Eclipse Aviation Walled Lake, MI MECHANICAL SYSTEMS PROJECT ENGINEER: Developed, engineered & managed an ECS, VCS, bleed air & de-ice system per FAR 23, & FAR 25. This included defining the required cooling, heating & ventilation flow systems' performances to meet FAA requirements. Wrote & presented components & systems' performance specifications. Evaluated vendors' proposals including unit costs, NRE, technical solutions, & products' compliance. Selected vendors supplying components for the ECS, VCS, de-ice, & fuel system. Managed Air to Fuel heat exchanger design, performance specs, vendor selection & integration into the wing faring. Presented system designs to FAA to identify certification compliance & test plans. Developed ECS & VCS test schedules, & needs for iron bird testing, & flight testing. Managed design, analysis, & test teams for ECS, VCS, fuel & de-ice systems. Generated fluid & thermal models using Excel, hand calcs, & Flowmaster 2, for predicting the performance of de-ice, ECS & VCS systems & components. Evaluated results of Fluent thermal models. Analyzed aero test/model data to best locate penetrations for RAM inlets & exhaust (correlating with the pressure maps of the aircraft). Conducted acoustic (insulation & muffler) studies of aircraft's mechanical systems. Developed temperature control algorithms for the cabin's climate zones. Develop & define I/O for ECS. Specified insulation requirements of aircraft.

3/1999 to 11/2000 Pratt & Whitney W. Palm Beach, FL COMPOSITE PROJECT ENGINEER SENIOR: Patents pending for designs of composite JSF "External VPCT", to improve stall margin, & serviceability while reducing engine weight (by 15 Lbs) & cost (by $80K/engine.) Developed design & process changes to remedy rubstrip disbond, & acoustic liner delamination. Developed field repairs & fly back limits for delaminated, & torn acoustic liners. Redefined potting spec for acoustic liners in bypass sections. Researched non-deflagrating abradeable compounds. Made engineering changes for PW4000/2000 abradeables. Compared ANSYS predicted models of rotors & stators, with holography images taken during vibration testing. Utilized steriolithography, for rapid prototyping of F119 composite stator tooling & rotor testing. Developed Business Case Studies for F119 inlet case & fan case Low Observable coating treatments. Performed hand stress calculations. Analyzed PATRAN data, normalized data, reduced data, & created Goodman & Campbell diagrams. Defined composite stators' ID & OD airfoil fillet join cores "noodles".

7/1996 to 1/1999 Boeing Co. (Phantom-Works) St Louis, MO MECHANICAL SYSTEMS ENGINEER SR: Designed C-17 composite horizontal stabilizer's air load rib structure & titanium splice plate. Performed kinematics analysis of motor linkage, cam, springs & pneumatic dampening. Designed cooling system & structure for ITER (fusion reactor) core. Redesigned Apache Longbow engine nacelles for produceability. Designed Apache crew station's ORT. Developed Apache trainer VCS, & air distribution system. Designed 360 deg "clam shell" visual projection screen system for VIDS flight simulator. Created UGII models of F-18 wing spars & kick ribs for IGRIP virtual manufacturing assembly.

6/1995 to 7/1996 GE, Aerojet, & Northrop various locations QUALITY ENGINEER: Programmed and operated CMM, inspecting machined airframe structures, combuster assemblies and tank killing ballistic projectile profiles.

2/1995 to 6/1995 Rolls Royce-Allison Engines Indianapolis, IN MECHANICAL & OIL SYSTEMS PROJECT ENGINEER: Conducted Continuation Improvement Programs on the T56 engine's (used on C130) gear box oil pump design for negative "g" flow capacity improvements. Defined test parameters & analyzed telemetry flight test data.

7/1986 to 1/1994 McDonnell Douglas Long Beach, CA MECHANICAL SENIOR SYSTEMS TEST ENGINEER: Designed ACES II ejection seat test equipment and conducted production testing of ACES II ejection seats. Conceived & designed high temp, high pressure proof tests, & high flow function tests for supporting MD-80, & MD-11 ECS. Developed wind tunnel RAT testing of ALQ pods. Engineered, & supported MD-90, & T-45 ram air turbine, pitot tube, oxygen, fuel, wing fuel tanks & hydraulic systems' ground & flight tests & support equipment. Conceived, developed & designed AOA, Gunsight, IRS, AHARS, & HUD systems' optical & laser alignment & installation procedures & equipment. Designed flight controls, landing hook, & landing gear rigging kits.

EDUCATION: BS Physics & BS Mathematics Eastern Michigan University

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