Product Design Mechanical Engineer

Kenneth J. Chung

*** **** ******* ** • Lindenhurst, Illinois 60046 • *******.*.*****@*****.*** • 224-***-****

Degreed mechanical engineer with over 25 years experience in product design engineering. Twenty one years experience in design and direct injected 2-stroke marine outboard engines, boats and product concepts. Experience in medical product design, plastic parts and assemblies. PTC Creo user since 1997, over 10,000 hrs in Creo product design and drawings. Ability to create and modify complex parametric 3D surfaces in Creo Parametric. Proficient with FEA linear and nonlinear static structural and dynamic analysis including explicit FEA using Ansys LS-Dyna. Ability to work on multiple projects in parallel. Issued eight patents for product design.

Core Competencies

●PTC Creo Pro/Engineer CAD design

●Ansys Finite Element Analysis, nonlinear static & dynamic

●Direct Injection 2-stroke engine component design

●Advanced conceptual design & prototyping

●Aluminum part design using lost foam, die casting

●Rotomolding part design

●Mass and Cost reduction

●Design for manufacturing and assembly

●Design for Six Sigma Tolerancing

●Plastic injection & Thermoformed molded parts

●Aluminum extrusions & sheetmetal

●Mechatronics assemblies - design and mechanical layout

Education and Credentials

Professional Masters of Science in Mechanical Engineering Illinois Institute of Technology – Chicago, Illinois

Bachelor of Science in Mechanical Engineering University of Illinois – Urbana/Champaign – Champaign, Illinois

Professional Experience

BRP USA, INC. OUTBOARD ENGINES DIVISION - Sturtevant, Wisconsin Aug 2003 – June 2025

BRP is a world leader in the design, manufacturing, distribution, and marketing of motorized recreational vehicles and powersports engines.

BRP USA, INC - Senior Design Engineer (2024-June 2025)

Manitou Pontoon Boats

oMechanical layout and component design of original and lightweight revision of Max Deck hatch system

Rigging integration of network cables, oil tank, airboxes and rigging tubes

oOil tank design for rotomolding process

oAirbox design using plastic thermoforming process

oDesigned components and assembles for an all electric powertrain for a pontoon boat

Advanced Concepts Development

oDeveloped conceptual design Creo models for new hybrid electric powertrains and range extenders with potential use across multiple divisions of the company.

BRP USA, INC - Senior Design Engineer (Sept 2014-2024)

Intake System

oDesigned components for large servo motor controlled ball valve assembly for the intake system. High performance at lowest possible cost.

oDesigned air duct and plenum assembly optimized for minimal NVH.

Simulation and analysis

oDesign optimization for strength, stiffness, and mass reduction and NVH with using Creo Simulate & Ansys

Linear and non-linear structural FEA analysis.

NVH reduction using modal analysis and structural dynamics.

Fuel Injector Project Management and Design

oCoordinate all phases of the project including project management, design, and engineering validation.

oLead cost reduction effort for fuel injectors providing annual savings of over $300K.

oSupport 2-stroke thermodynamic development engine with Pro/E surface models and design of prototype hardware.

Outboard Controls Design

oLead mechanical design of control joystick and electronics modules accessory for new dual engine application.

oLead mechanical design for new low cost accessories with projected $1mil cost savings annually. Performed all mechanical component design and detailing of parts and assemblies.

Advanced Concepts Development

oDeveloped conceptual design Creo models for new advanced engineering products with potential use across multiple divisions of the company.

oDesign and develop initial prototypes of new product concepts

BRP USA, INC - Senior Design Engineer – Functional Technical Lead (May 2010 – Sept 2014)

Powerhead Group

Engineering Functions

oLead design, documentation, and analysis efforts to support component and system design.

oCreate component and assembly level specifications for new products.

oCollaborate with other development engineers and supplier quality engineers to create validation test plans.

oSupport 2-stroke thermodynamic development engine with Pro/E surface models and design of prototype hardware.

oPerform structural FEA using Creo/Simulate and Ansys. Analyze and evaluate experimental and simulated results.

oDeveloped top-down structured architecture for Creo models for lost foam engine block design.

oLead prototyping and development efforts for a hydraulically actuated variable valve timing in an outboard engine.

oDesigned a precision fuel metering check valve for direct fuel injector, drastically improving consistency of fuel delivery.

Lead cross functional team in design of direct injected 2-stroke engine parts and assemblies

oWork closely with manufacturing engineering to provide designs for cost effective manufacturing without sacrificing design requirements.

oWork with development engineers to specify testing for validation and resolve development issues.

oTeam leader in SAP product lifecycle management (PLM) system for powerhead components for engineering change requests, incoming inspection reports and deviations for new and current product.

oIdentify technical, schedule, or cost issues requiring management intervention.

oIdentify and implement technical solutions for problems in the field.

Provide project management support within the design group for new product development.

oCreate and maintain timelines to support required product development schedules for critical issues.

oEnsure project schedule adherence by flushing out technical or supplier issues.

oDocument open issues and identify/track action items and follow ups.

oManage resource leveling within and in between design teams.

BRP USA, INC - Senior Design Engineer (July 2008 - May 2010)

3D modeling and prototyping of the next generation of outboard engines for higher power, reduced emissions, and fuel economy.

BRP USA, INC - Product Designer (Aug 2003-July-2008)

Design and development of outboard engine components, including engine block, cylinder heads, motor covers, various metal & plastic parts.

Creo part design of components and assemblies of fuel injector. Work with suppliers to resolve engineering/manufacturing/quality issues

Perform Pro/E Mechanica structural simulation FEA for optimized part design

DESIGN DEPARTMENT INC. 2013 - 2022

Senior Design Engineer Contractor (2nd job)

Retained contractor on as-needed basis for design concept ideation, design and development, and structural analysis of parts and assemblies. Assist in a wide variety of projects from medical devices to heavy vehicle accessories.

Medical Devices

Collaborate in design concepts for new medical products using Creo Parametric.

Structural analysis and design optimization of ostomy products, intubation devices, and suction canisters using Ansys explicit FEA, LS-DYNA and Creo Simulate

Design of a cost reduced medical suction pump assembly

Design and develop manufacturing assembly and test fixtures for suction pump cartridge sub-assembly

MOTOROLA, INC. – Libertyville, Illinois Sept 1996 - Aug 2003

Senior Engineer

Designed in-vehicle and personal accessories for multiple cellular phone platforms.

Designed a cost reduced version of external housings for modular cellular phones.

Designed and patented an non-metallic spring solution for a rotating belt holster clip mechanism

Create Pro/Engineer parts (involving complex surfacing), assemblies, and drawings.

Develop engineering specifications for accessory products.

Validate product design through design verification testing in the reliability lab.

Design of lifecycle test fixtures for product reliability testing.

Resolve engineering issues of current products.

Work with suppliers from concept through product end-of-life.

METHODE ELECTRONICS, INC. – Rolling Meadows, Illinois June 1994 - Sept 1996

Mechanical Engineer

Design of power bus bars for commercial and industrial products. Provide technical support to customers to improve designs, lower costs, and increase the manufacturability of parts.

Responsible for coordinating and completing multiple projects from preliminary designs. Major projects include Motorola Iridium and Space Station Freedom.

Design of fixtures, tooling & gages associated with fabrication, assembly and inspection of parts.

Create engineering drawings and bills of materials.

Assist in quotations and evaluations of preliminary designs.

SOLEQ CORPORATION – Chicago, Illinois May 1992 - June 1994

Junior Mechanical Engineer

Design parts and vehicle modifications for conversion of 1994 Ford Escort station wagons to electric vehicles

Coordinate and perform part fabrication, vehicle modifications, and installation of components with technicians and machinists.

Provide time and cost estimates of vehicle conversions.

PSW INDUSTRIES, INC. – Chicago, Illinois June 1991 – May 1992

Designer

Provided design and engineering support for electric motor and transformer laminations.

Create engineering drawings for sheet metal stampings.

Design chute layouts, gages, and pressroom tools.

Professional Affiliation

American Society of Mechanical Engineers

Registered Engineering Intern

Patent List

8925502 Hydraulically actuated valve assembly for an engine

10723429 Power steering system for marine outboard motor

12067814 Marine motor assembly and method for testing a water resistance of a motor unit housing of a marine motor assembly

W02007005632A1 Fuel injector nozzle manufacturing method

11046411 Tiller assembly for a marine outboard engine

11148776 Tiller system for a marine outboard engine

US20240416020A1 Spherical canister

US6,443,340 B1 Spring system for cellular phone holster

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