Senior Design Engineer

Michael Mattaous

*********@*****.*** +1-714-***-**** Huntington Beach, CA https://www.linkedin.com/in/michael-mattaous-6b57a119a/ Skills

● Solidworks

● Siemens NX

● Creo Modeling

● Teamcenter & PDM

● GD&T ASME Y14.5

● Finite Element Analysis

● Rapid Prototyping & 3D Printing

● Research & Development Experience

● Project Management

● Mechatronic Applications

● Statistical & Tolerance Analysis

● Systems Engineering Experience

Professional Experience

ASML

Senior Design Engineer September 2024 – March 2025 Location: San Diego, CA (Contract)

• Designed and optimized unique tooling and fixturing via Unigraphics for semiconductor products, integrating DFM/DFMA across all design cycle stages.

• Led cross-functional collaboration with engineering, manufacturing, and QA teams to develop, qualify, and document low & high volume products and tools.

• Managed PDM files, bi-weekly scrum meetings, and project planning, including deliverables, budgets, timelines, and driving supplier procurement efficiencies.

• Prototyped and iterated products via rigorous development processes circumventing engineering challenges while improving functionality, durability, timeline.

• Developed complex mechanisms, BOMs, technical design documentation, and assemblies in Siemens NX, subjected designs and prototypes to rigorous testing. Terran Orbital

Mechanical Design Engineer October 2022 – May 2024 Location: Irvine, CA

• Designed and developed full scale end to end automation systems and processes to manufacture ranging size and spec satellites on the modular and vehicular level.

• Orchestrated top down system designs for full vehicle level automation, module level automation, and various relative mechanical subsystem configurations.

• Piloted novel system architectures for vehicle automation, leading to an average 50% increase in manufacturing efficiency cutting rework by 15 hours per week.

• Designed fixturing, end of arm tooling, pneumatic assemblies, 80/20 structures, tool changers, mounts, lifts, systems, highly detailed drawings and assemblies.

• Delegated engineering tasks and timelines to engineers and interns, redlined drawings and assemblies, and approved finalized work for system integration.

• Validated concepts via FEA, resolving abstract challenges in early and mid-stage development; simulations decreased prototype iterations and accelerated timelines.

• Implemented automation efforts via DFA, cut processing time and labor hours of satellite manufacturing, increased output by 540%, decreased failure rate by 70%.

• Adapted and simulated solutions which upscaled production devices, not originally made for mass quantity fabrication while retaining redundancies and constraints.

• Integrated robotic arms, injectors, vacuum systems, etc into satellite assembly line of first large scale automation effort applied to nano and micro satellites.

• Oversaw multiple projects, created workflows for and trained technicians, interns, other engineers, and managed a large 3D print farm working with 20+ materials.

• Drafted drawings, contracted vendors, dispatched purchase orders, oversaw procurement, developed and managed project assets, workflows, & relevant procedures.

• Modeled and meshed over 100 CAD models for technician VR/AR training programs utilized for real time satellite assembly build visualizations and tutorials.

• Engineered and constructed multiple satellites via additive manufacturing, subtractive manufacturing, and multi-material composites for procedure generation, harnessing layout planning, and business development operations which directly netted several private and government contracts exceeding $200 million.

• Collaborated with over a dozen teams on projects relating to design of batteries, modules, vehicles, assembly operations, harnessing, AI vision solutions, and more.

• Organized crossteam and supplier meetings, communicated with vendors to resolve lead time and technical issues and expediently manage supply chain operations.

• Assisted other teams that faced technical and supply issues, designed and implemented turn key solutions within a restricted time frame to meet customer demand.

• Spearheaded additive manufacturing initiative for flight ready hardware to automate part generation, applied components to vehicle series saving $1.2 million.

• Performed end to end operations including concept generation, mechanical design, drawings, outsourcing, vendor outreach, assembly, commissioning, and support. Midmark Corporation

Mechanical Design Engineer February 2022 – September 2022 Location: Irvine, CA (Contract)

• Developed automation fixtures and software solutions to test medical devices including vital monitors, spirometers, and ECGs, through virtual machines.

• Drafted quality documents for V&V of test fixtures, design verification for experiments, maintained calibration for QA measuring devices and fixtures, wrote SOPs.

• Developed python scripts to reform inefficiencies in automations, utilized and composed g-code to GRBL for CNC milling and 3D printing platforms.

• Created and maintained virtual machines via VMware and Microsoft Azure for program testing purposes, conducted software testing on virtual machines.

• Aided in software and hardware integration for testing unit functionality and debugging of software and hardware errors present in automation systems.

• Constructed materials lists, component exchange schedules, performed supplier outreach, calibration log procedures, and travel logistics as needed.

• Created cost-effective solutions and optimizations to automation fixtures, implemented measures that increased efficiency by up to 33% and cut waste.

• Incorporated efficiencies and preventative measures into testing fixtures, coordinated with engineers for scrum work review and workflow management.

• Consolidated issues and troubleshooted corresponding fixture defects, collaborated with engineers of varying disciplines to resolve multifaceted PLM issues.

• Coordinated training to other engineers regarding procedures, operations, and in technical matters including research, development, and debugging. Edwards Lifesciences

Transcath Mitral Tricuspid Therapies (TMTT) R&D QA Biomedical Engineering Tech March 2021 – October 2021 Location: Irvine, CA (Contract)

• Devised test methods and built complex prototypes to develop feasibility testing fixtures for heart valve migration & next gen heart valve testing.

• Performed operational testing, Gage R&R, root cause analysis in test model designs, DOE, engaged in process development, and iterated on test models & methods.

• Developed Instron test methods and specified test fixtures via wet lab for feasibility studies. Defined design controls, analyzed, and performed statistical analysis.

• Presented data systematically collected from testing research, provided observational conclusions clarifying outcomes pertaining to various cardiac studies.

• Documented test data and employed a variety of research methods; consulted with dedicated teams to determine progress and future phases for studies.

• Operated on accelerated wear testing studies for differing heart valve types utilizing new technologies for mitral and tricuspid valve replacement therapies. Mechanical Design Engineer

Research & Development Mechanical Engineer November 2019 - December 2020 Location: Long Beach, CA

• Operated under PhD with a multidisciplinary team to develop a fully functioning metal 3D printer prototype; budget $10,000; 1’x1’x’1 build area.

• Fabricated designs of parts, assemblies, and drawings in Solidworks; adapted CAD components to continuously implement iterative optimizations.

• Conducted research and testing of prototypes for build plate, halogen lamp, powdered metal injection system, and unified layer bonding agents.

• Experimented with distinctive product designs for powder injection and heating methods to ensure durability and quality of brass/aluminum material prints. Projects

Prosthesis Aide Research Project

• Managed team of 5 persons to design an electro-mechanical walk-assist device for individuals with light to moderately impaired mobility.

• Research included kinematic calculations to match the gait of average walking behavior; calculations used to design parts with system constraints in mind.

• Manufactured prototypes via 3d printing and machine shop; changes validated after technical documentation & CAD drawings submitted for review.

• Utilized microcontroller, drivers, stepper motors, and a myofascial sensor with 3 electrodes to detect muscle flexion, programmed to react to user input. Autonomous Drone CAD Project

• Lead 4-person team to design Emergency Medical Drone capable of autonomously transporting medical equipment to emergency sites.

• Performed cost benefit analysis and ran simulations for region specific weather conditions for seamless flight with first aid payload.

• Executed FEA stress tests on various polymers for drone body construction, integrated break points to absorb impact up to 400 ft drops. SAE Vehicle Design & Additive Manufacturing Project

• Worked with a large team on design, manufacturing, and construction of off road vehicle model according to SAE competition standards.

• Aided in the powertrain team to optimize subsystem output as well as complete engine teardown and reconstruction, utilized team expertise. Education & Certifications

• Bachelor of Science, Mechanical Engineering California State University Long Beach (August 2017 - December 2020)

• CAD Design Professional Certification(CSWP) Dassault Systems C-WZYF26C9AX (March 2025)

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