Design Engineer Flight

FRANK MAYO

AIRCRAFT DESIGN ENGINEER

FLIGHT CONTROLS – MECHANICAL SYSTEMS – STRUCTURES

** *** **** ** & 25 GENERAL AVIATION

MILITARY, PROTOTYPE & LOW OBSERAVBLE (STEALTH)

HELICOPTER & VTOL

REUSUABLE SPACE VEHICLE

Permanent Address: 10 Audubon Hill Way Unit 301, Arden NC 28704

Phone: 828-***-****

Email: ********@*****.***

Experience Summary:

Design and Liaison Engineer on numerous general aviation, military, prototype, and space vehicle programs responsible for configuration, structure, mechanisms, actuators, flight controls, mechanical systems, 3D model validation and flight test equipment. Responsibilities have included oversight of concept development, design, fabrication, assembly, installation, and the writing of static-functional test plans. Management of flight test programs, and the writing of pilot operating handbooks and final reports for FAA certification. Consultant to a major national newspaper on aircraft and flight control systems design. Computer aided design proficient with approximately sixty-five thousand hours of CATIA, CADD and Unigraphics. Excel, Word and Power Point proficient.

Aircraft:

Bell V-22 aircraft & FARA prototype helicopter

Cessna business jets

Gulfstream G-IV & G-V aircraft

Gulfstream G550 special mission aircraft

Lockheed F-22 & F-35 aircraft

McDonnell F-18, F-15E, FA-18 E/F, ATF-23, NATF-23 & A-12 aircraft

Northrop-Grumman E-2D & TX prototype trainer aircraft

Piper Malibu, Meridian, Piperjet & Altaire aircraft

Sikorsky Blackhawk, Seahawk & CH-53 helicopters

Stratolaunch reusable space vehicle

Textron Scorpion ISR prototype aircraft

Toyota Advanced prototype aircraft

Virgin Galactic/Spaceship Company spaceship

Fairchild Dornier 328 aircraft

Airbus A400 transport aircraft

Honda HA-420 business jet

Computer Aided Design Systems:

CATIA V2, V3 & V4 - 35,000 hrs.

CATIA V5 & V6 - 10,000 hrs. (Enovia, Smart Team & Agile)

Unigraphics versions 12 through 18 - 2,000 hrs.

UG NX2 through NX10 - 8,000 hrs. (Teamcenter)

CADD - 10,000 hrs.

Clearances:

DOD Secret (Inactive)

Air Force Special Access (Inactive)

Department of Navy Special Access (Inactive)

Education:

Eastern Florida State College–General Studies

East Tennessee State University–Mechanical Engineering Technology Major

Work History:

Jan. 2020-Present

SELF-EMPLOYED/SEMI-RETIRED

Semi-retired to Florida in hopes of procuring part-time aircraft design work. Relocated to North Carolina in July 2021 due to the negative impact on the aircraft industry of the Covid pandemic.

April 2019-Jan. 2020

BELL HELICOPTER, Ft. Worth, TX

FLIGHT CONTROLS & MECHANICAL SYSTEMS DESIGN ENGINEER (Contractor)

Responsible for cockpit and tail rotor fly-by-wire flight controls design and installation. Developed unique weapons storage and deployment mechanism for the prototype Future Attack Reconnaissance Aircraft (FARA). Work was performed with CATIA V6.

Oct. 2018-April 2019

Sabbatical from traveling to return home.

July 2018-Oct. 2018

NIAR, Wichita, KS

MECHANICAL DESIGNER (Contractor)

Assigned by NIAR to Bombardier for flight testing and flight controls non-conformance resolutions on the Global 8000 aircraft. Work was performed with CATIA V6.

Dec. 2017-July 2018

Sabbatical from remote consultant position after completing assignment with Stratolaunch Systems.

Aug. 2017–Dec. 2017

STRATOLAUNCH SYSTEMS, Seattle, WA

FLIGHT CONTROLS DESIGNER (Remote Consultant)

Design of flight controls and control surface actuation systems for a Mach 30 reusable space vehicle of comparable size to the Space Shuttle. Duties included definition of flight controls architecture, trade studies of various controls systems and working with NIAR, Wichita, KS and NASA Ames Research Center, CA to establish design guidelines. Work was performed with CATIA V5/Enovia.

April 2016-Aug. 2017

GULFSTREAM AEROSPACE CORP., Savannah, GA

SPECIAL MISSIONS DESIGN ENGINEER (Contractor)

Antenna, radome, surveillance pod and aerial refuel system design and manufacturing liaison on the G550 AWACS type aircraft. Lead of aerial refuel effort. Work was performed with CATIA V5/SmarTeam.

May 2015–April 2016

NORTHROP-GRUMMAN CORP., El Segundo, CA

MECHANICAL DESIGN ENGINEER (Contractor)

Responsibilities were oversight of design of the canopy, canopy open-close and latch mechanisms, and cockpit fly-by-wire flight controls installation on a proof of concept T-X trainer aircraft. Work was performed with CATIA V5 and NX 10/Enovia.

Dec. 2014- May 2015

CESSNA AIRCRAFT, Wichita, KS

FLIGHT CONTROLS DESIGNER (Contractor)

Responsible for design and manufacturing and rigging of flight controls for the next generation of Cessna business aircraft and the writing of test plans. Work was performed with CATIA V6.

July 2014-Dec. 2014

Hiatus from work to collaborate with the Wall Street Journal on the risks associated with experimental space vehicle control systems post Virgin Galactic spaceship mid-air breakup.

March 2013-July 2014

VIRGIN GALACTIC/THE SPACESHIP COMPANY, Mojave, CA

FLIGHT CONTROLS DESIGNER (Contractor)

Responsible for improvements to the flight controls on the SS2 Spaceship in a rapid prototype environment. Duties included ensuring that designs conformed to Federal Regulations and coordination of manufacturing. Work was performed with CATIA V5/Agile.

Feb. 2012-March 2013

TEXTRON/AIRLAND, Wichita, KS

PRINCIPAL FLIGHT CONTROLS DESIGN ENGINEER (Contractor)

Responsible for development of flight controls and canopy open-close actuation system for the prototype Scorpion high performance ISR aircraft. Oversight of design and manufacturing of cockpit through surface controls, flap actuation and flap tracks. Work was performed with CATIA V5/Enovia.

March 2011-Feb. 2012

PIPER AIRCRAFT COMPANY, Vero Beach, FL

PRINCIPAL FLIGHT TEST EQUIPMENT DESIGN ENGINEER (Contractor)

Responsible for development of flight test equipment for the Altaire jet aircraft. Oversaw design of the nose boom, pilot emergency egress system, blow-off egress door and spin chute. Work was performed with Unigraphics NX5/Teamcenter.

June 2010-March 2011

AAR CORP., Goldsboro, NC

MECHANICAL SYSTEMS DESIGN ENGINEER (Contractor)

Responsible for design of cargo handling systems on the Airbus A400 aircraft. Duties included the engineering of roller pallets and cargo latch/de-latch mechanisms. Work was performed with CATIA V5/Enovia.

Nov. 2008–June 2010

SIKORSKY AIRCRAFT, Stratford, CT

FLIGHT CONTROLS & MECHANICAL SYSTEMS ENGINEER (Contractor)

Responsible for resolving flight controls manufacturing non-conformance and rigging issues on the Blackhawk and Seahawk and layout of flight controls components on the CH-53 helicopters. Work was performed with CATIA V4-V5/Enovia.

July 2007–Nov. 2008

PIPER AIRCRAFT COMPANY, Vero Beach, FL

PRINCIPAL FLIGHT CONTROLS DESIGN ENGINEER (Contractor)

Responsible for design, manufacturing, installation, and testing of the flight controls for the Piperjet FAR Part 23 aircraft. My responsibilities included development of a side-stick controller, design of flaps, aileron, rudder and elevator controls, engine nacelle, cargo door spider gear mechanism and the writing of functional test plans and the Pilot Operating Handbook. Work was performed with UG NX3 & NX5/Teamcenter.

June 2006–July 2007

NORTHROP-GRUMMAN CORP., Bethpage, LI., NY

FLIGHT CONTROLS DESIGN ENGINEER (Contractor)

Responsible for modifying the hydro-mechanical flight controls, design of mechanisms for control surface position indication and development of a deployment mechanism for an in-flight antenna on the E-2D Advanced Hawkeye aircraft. Work was performed with CATIA V4.

July 2005-June 2006

LOCKHEED-MARTIN, Fort Worth, TX

MECHANICAL SYSTEMS DESIGN ENGINEER (Contractor)

Designed the hydro-mechanical aerial refueling probe on the F-35 fighter aircraft. Work was performed with CATIA V4.

Nov. 2001-July 2005

TOYOTA AVIATION BUSINESS DEVELOPMENT OFFICE, Torrance, CA

FLIGHT CONTROLS DESIGN ENGINEER (Contractor)

Responsible for engineering, manufacturing, and functional testing of the flight controls for a FAR Part 23 prototype aircraft. I designed a unique side stick controller, wrote the functional test plans and Pilot Operating Handbook, and developed various configurations for future aircraft. Work was performed with CATIA V4.

Sept. 2001-Nov. 2001

Inactive due to 911 event

Jan. 2001-Sept 2001

HONDA AIRCRAFT COMPANY, Greensboro, NC

STRUCTURES & FLIGHT CONTROLS DESIGNER (Contractor)

Design of metallic wing components and trim actuation mechanism for the HA-420 FAR Part 23 aircraft. Work was performed with CATIA V4.

April 2000-Jan. 2001

NORDAM GROUP, Tulsa, OK

MECHANICAL SYSTEMS DESIGNER (Contractor)

Design of nacelle, fuel system components and thrust reverser on a Pratt & Whitney-Canada prototype turbofan engine. Work was performed with CATIA V4.

Oct. 1999-April 2000

GULFSTREAM AEROSPACE, Savannah, GA

DESIGN & LIAISON ENGINEER (Contractor)

Responsible for the design of the G-IV prototype satellite communications radome that was incorporated into the production aircraft. Coordinated the manufacturing and installation of the radome at various completion centers and assisted with documentation for issuance of a Supplemental Type Certificate. Work was performed with CATIA V4.

April 1998-Oct. 1999

PIPER AIRCRAFT COMPANY, Vero Beach, FL

STRUCTURES DESIGNER (Contractor)

Responsible for design of the horizontal stabilizer and elevator on the FAR Part 23 Malibu-to-Meridian conversion. Work was performed with Unigraphics Version 18.

April 1997-April 1998

NORDAM GROUP, Tulsa, OK

SYSTEMS DESIGNER (Contractor)

Design of nacelle doors, pylon, and fire suppression systems on the Dornier 328 aircraft engine. Assisted with documentation for JAA certification. Work was performed with CATIA V4.

Feb. 1993-April 1997

GULFSTREAM AEROSPACE, Savannah, GA

STRUCTURES & MECHANICAL SYSTEMS DESIGNER (Contractor)

Responsible for design of G-V aircraft metallic and composite fuselage, engine pylon and nacelle components. Originated models of flaps and flap tracks. Designed the engine thrust strut, APU ram air inlet, wing-to-body fairing and associated structural components. Work was performed with CATIA V4.

June 1978-Jan. 1993

McDONNELL DOUGLAS, St. Louis, MO

STRUCTURES & MECHANICAL SYSTEMS DESIGNER (Direct & Contractor)

Responsible for design of structure, mechanical systems, and flight controls on the F-18, F-15E, ATF-23, A-12 and NATF aircraft. Beginning in 1980, work transitioned from manual to CADD, Unigraphics and CATIA V2-V4.

Covid Vaccine Status: Vaccinated February & March 2021 – Booster December 2021

References furnished upon request

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