Design Engineer Systems

SUMMARY: Highly skilled Mechanical Design Engineer with over (25) years of experience working aerospace, automotive and military off road vehicles. Commercial and Military Aircraft, Helicopters and ground vehicles. Systems Design, Airframe/Structures, installations utilizing Catia V5 and NX12. Experience supporting ECS, Flight Controls, Flight Deck, Electrical Sub Systems, Hydraulic Mechanical systems and cooling systems.

Manufacturing Processes: Stampings, Injection Mold, Blow Mold, Rotational Mold, Hydro/Bladder Press, Castings, Forgings, Sheet Molded Compound/SMC, Carbon Fiber, NC Mills/Lathes, Electrical Component, harness and flat pattern design.

EMPLOYMENT HISTORY:

Mechanical System and Design Analysis Engineer Nov 2022 to Sep 2024

Boeing / The Structures Company LLC Everett, WA

777x support the development and documentation of mechanical and fluid system and thermal environment requirements to establish the system design. Encouraging high aircraft performance while operating in compliance with regulatory (FAA, EASA, etc.) requirements. Support supplier maintenance, or modification of system, component, and installation designs/proposals to provide design documentation to downstream groups development, test, and production activities. Requirements Validation and Verification for aircraft certification.

Mechanical Systems Design NX-12 Oct 2019 to May 2020

AeroTEC LLC (Testing, Engineering & Certification) / Noramtec Seattle, WA

Rolls Royce Flying Test Bed 747-400. Modified existing design to retrofit into a flying test bed for regional & long-range propulsion systems testing. Design of the Hydraulic and electrical load bank cooling systems including heat exchangers, oversized NACA inlet and ducting mounted in the Wing to Body fairing area. Design new structure to tie into existing structure and center fuel tank.

Mechanical Systems Design & Analysis Engineer CATIA-V5 Jan 2019 to June 2019

Boeing / Artech Information Systems Everett, WA

Supported the development and documentation and qualification of mechanical and fluid system and thermal environment requirements to establish the systems design. Performed verification and validation of component level requirements to approved processes and tools. Supported development, maintenance or modification of system, component and installation designs & proposals. Provided design documentation to downstream groups. Performed and documented analyses to validate and qualify that systems and components meet requirements and specifications. Supporting system components designs/proposals & standards to provide installation and detailed documentation. Worked with supplier for identification and review of supplier design changes for acceptability, impact and qualification.

Airfame & Systems Design Engineer CATIA-V5 Nov 2017 to Dec 2018

Boeing / US Tech Solutions Charleston, SC

787 Crown Re-design. Responsible for 787 (-9) (-10) SEC 43 on a team dedicated to create a modular installation of ECS systems to be assembled on modular installation tool, then installed as modular system. The goal was to insure a more consistent build. Module system provided wire bundle supports, equipment supports and tooling provisions. Responsible for airframe modifications and structural design changes. Modular system contained all systems in the crown.

Mechanical Design Engineer CATIA-V5 Jan 2009 to Mar 2017

Boeing Design Center / Chipton Ross Ridley Park, PA

Boeing-Sikorsky Defiant JMR-TD Joint Multi-Roll Tech Demonstrator. Dynamic Systems-Transmission design-lube systems, shaft assemblies and locknut configuration.

Affordability team- provide engineering support to Boeing Commercial Aircraft as part of the 777, 767 and 737 Systems Design and Cost Opportunity Value Creation teams. Identified engineering projects that reduce the build cost. Investigated the business cases viability and implemented approved design changes. Investigation and support of customer field service issues. Commodities supported include ECS, Flight Controls, Flight Deck, Electrical Sub Systems and Mechanical Hydraulics.

787-10 Landing Gear hydraulics routing & Equipment Racks installation and electronic component installation

CH47-Chinook Tooling design for FLIR (Forward Looking Infrared Radar) on New G Build.

KC-46A (767-200) Military Tanker. Electrical harness design and hydraulic tubing design

777-300 Product Development for new systems layouts RSAT (Runway Situational Awareness Tool).

EMARSS Hawker / Beechcraft – “Enhanced Medium Altitude Reconnaissance and Surveillance System” military spy aircraft project. Equipment installation, structural modifications, straps, structural doublers, antennas, electrical rack installation, cabin hand held devices and related mounting brackets.

CH47-Chinook ECS - Preliminary layouts of heating system, ducts, air warrior system & equipment installation. Designed and released the hydraulic systems for Canada project, including the entire Cockpit, Electronics Closet, Heater Closet and both forward and aft Pylons using the Catia Tubing Workbench. Re-designed the Heater Closet hydraulics again for the U.S. MK6 to accommodate the external hydraulic rescue hoist. Designed and released all support structure and related installation drawings. During the initial production cycle, I worked in factory to give ship side support. This was the first build and required real time support to resolve any design issues on the fly. I also provided shipside support for the new build of the Canada program. Created presentations to present design issues and recommendations for group meetings. CSAR (Combat Search and Rescue) Chinook derivative air force helicopter project. Preliminary design concepts of airframe, structures and payloads using relational design. Soft trim/blankets, protective cargo buffer boards, Cargo Handling System, SICM’s, space reservation models of all flight controls using Kinematics to create swept volumes. Support newer V5 users in ECS group.

Systems Design Engineer CATIA-V5 Nov 2007 to Dec 2008 Nordam Group Inc / Butler Tulsa, OK

Propulsion Systems Design on regional jets. Projects include Hawker 4000, Dassualt Falcon 2000EX, Hawker / Beechcraft 427, Lear

Jet & Cessna. Design related to Nacelle systems and EBU (Engine Build Up), including electrical routing for FADEC, Power Feeders,

& all LRU installations. Released schematics & Form Board Drawings. Worked with vendors to specify elect. connectors, back shells & boots. Modifications to fire protection systems, hydraulics, bleed air de-ice protection and piccolo tube, pneumatic starting system, engine fuel, oil, & drain systems. Converted legacy PW308 program from Catia V4 to V5 and made required changes to engine and thrust reverser harnesses.

Systems Design Engineer CATIA-V5 May 2006 to Oct 2007

Boeing Corporation / Volt Everett, WA

787 Dreamliner - wire installation integrator for design & engineering of entire interior electrical systems. Ensured bundles were functional, had proper shielding and grounding and mounting provisions and could be assembled to equipment on all interior monuments. Supplier integration, communicate between business teams, vendors and partners using architecture drawings, Power Points and Excel to facilitate big screen reviews using IVT and Enovia. Ensured FAA & Boeing requirements were met.

Sr. Mechanical Designer Catia V5 Jan 2005 to Apr 2006

Oshkosh Truck Corporation Oshkosh, WI

Lead designer on military heavy truck-5 axle, all-wheel drive, 3 axle steering program. Responsible for structures, power train, cooling system, air system including turbo & C.A.C. (Charge Air Cooler), steering, suspension, layouts and installations.

Coordination with the team of designers & builders. Adherence to C130 aircraft & railcar standards to insure transportability.

Design / Project Engineer Catia V4-V5 Jan 1989-Dec 2004

Condensed Auto Industry Experience Detroit, MI

Interior trim components-carpet, soft trim, hard trim, acoustic sound barrier. Forward/rear exterior lighting-including lens design & pillows for reflection angles. Assign and monitor design projects to Design Engineers to ensure schedules are were. Exterior “Class A” surfacing for Daimler Chrysler studio. Generated studio surfaces for new products to reflect clay models. Design interior trim, seating, carpet, insulation, lighting, ducting & louvers. Front & rear fascia’s and sheet metal to reflect clay models. Saturn inside, outside door handles & all related mechanisms. Interior injection mold door trim panels. Air Conditioning ducting using blow mold. Manager - Cadillac Mock-Up, Body Division - managed the body division for Cadillac to build full scale prototype vehicles to engineering design & specifications on full scale surface plates using CMM (Coordinate Measurement Machines). Facilitated weekly mock-up reviews to keep engineers current of the latest changes and to ensure model integrity.

Expert Design & Engineering Services LLC Catia V4-V5 Jan 1999-Dec 2001

Owner / Consultant - Automotive Design Company Detroit, MI

Responsible for sales, project management, timing, product design & engineering through release. Leasing of computer hardware, software (Catia) & supplying engineering resources, consulting & training. Developed GD&T schemes to insure fit and function.

Catia specialist trainer, supported users in all phases of design from basic through advanced courses at various Chrysler facilities.

Coordinated the build of full-scale models/bucks separate interior and I/P models. Assigned projects to Modelers and managed staff.

EDUCATION:

National Graduate School Falmouth, MA

Bachelors of Science - Quality Systems management

Lawrence Technological University Mechanical Engineering Technology Southfield, MI

Software/Skills: CATIA V5 (20,000 + hours), NX 12 (1,500 hours)

Enovia, Smarteam, TeamCenter, IVT, DOORS, VPM, Windows, Excel, PowerPoint, Adobe, MS Word, MS Outlook.

Additional Education and Training:

Igor Sikorsky University- Online -ENOVIA- Ridley Park, PA

Prerequisite training to supporting Sikorsky-Boeing Joint Multi-Role Technology Demonstrator.

CATIA V5 – Boeing - Relational Design, Kinematics, Airframe Design Fundamentals, Airframe Stress Fundamentals, Assembly Design, Smarteam, Sketcher, Part Design, Drafting, Wireframe/Surface Design, Sheet Metal Design.

Nagoya Gaukuin University Nagoya, Japan

One-year scholarship program-Studied Japanese language and culture

Licensed Private Pilot Oakland International Airport (KPTK) Pontiac, MI

Rating: Single Engine-Land

Endorsements include:

Complex

High Performance

Hobbies: Flying, Hunting, Fishing, Boating, Traveling, House Flipping, Antique Automotive Restoration.

Kitfox kit plane https://kitfoxaircraft.com/ Delivery - September 2024 Building a new 2024 Kitfox VI Super-Sport LSA kit plane from the Kitfox Corp.

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