Development Engineer Mechanical

Andres Garcia

CONTACT INFORMATION

**** ********** **, **********, ** 40228 615-***-**** ********@******.********.*** EDUCATION

Bachelor of Science in Mechanical Engineering and Applied Mathematics May 2015

Lipscomb University – GPA: 3.9 – Summa Cum Laude RELEVANT WORK EXPERIENCE

Ford Motor Company (contract to hire through Insight Global) August 2024 to Present Louisville, KY

Product Development Engineer (F Series Trucks, exterior focus)

Increased reliability and generated cost savings by binning claims from warranty services and collaborating with suppliers, design engineers, and sourcing to determine root cause in addition to short term and long term corrective actions.

Supported trials to document process improvements as well as new/replacement parts fit, form, and function. Evaluated equipment effectiveness at meeting desired quality based on binning statistics and error proofing data.

Investigated root cause for warranty claims pertaining to door latches, tailgate latches, tailgate step, ignition tumblers, door tumblers, and other locking/latching functions within the vehicle. Wabtec Corporation (contract to hire through Bentley Global Resources) May 2021 to June 2022 Wabtec Corporation (FT Employee) June 2022 to May 2024 Erie, PA

Packaging Engineer/Mechanical Engineer (Lithium-Ion Batteries for Locomotives)

Generated long term revenue from servicing of battery packs by collaborating with battery installers to design/build/validate a safe, efficient, and reliable product for installing/removing battery packs from locomotive (1400 to 1800lb battery packs). This included two different machine designs for two styles of battery packs (hybrid vs FEV) that ranged from a manual chain operated mechanism that allow forklift and crane interface to an under the hook crane operated device with a hydraulic tilt assist and speed control for fine adjustment. Both designs featured large weldments with bolt on components as needed to ensure full functionality. Analyzed maximum stress/deflection for each tool to ensure structural integrity/stiffness was adequate for installation footprint on locomotives and operator ability.

Provided technical expertise and design input during preliminary design, DFMEA, testing and production validation of venting system to minimize thermal runaway propagation in battery pack. Collaborated to develop prototype thermal runaway testing plans. Presented product validation plans for compliance with IEC 62619 & 62133 (market feasibility) and documented test results showing capability to prevent pack to pack propagation ensuring overall product safety/profitability.

Increased reliability and generated cost savings by vibration lifecycle testing clinch nuts and helicoils in aluminum and copper bus bar connections and optimizing via probabilistic bolted joint analysis across expected operating range including fatigue life considerations due to alternating vibration/thermal loads. Supported resistance testing of various joints in development of thermal model for control system.

Demonstrated feasibility of battery pack internal thermal runaway venting system via structural- thermal FEA, mitigating collapse risk and crack propagation. Andres Garcia

Enhanced reliability and profitability of NYCT hybrid battery pack through alternate end plate designs and pressure gradient improvements.

Increased safety and reliability of battery electric locomotive by designing and analyzing a chimney for venting thermal runaway gases from battery pack into atmosphere.

Aero Design Inc. September 2019 – August 2020

Mount Juliet, TN

Project Engineer (NiCd mainship and other chemistry emergency batteries for airplanes)

Implemented cost-saving measures for emergency batteries through reverse engineering of OEM foam spacers and battery cells.

Enhanced manufacturing efficiency by incorporating production staff feedback into work instructions and engineering drawings for aircraft assemblies. This included developing actual cost estimates for current equipment and comparing to new equipment and recommending replacing outdates equipment based on maintenance costs and low output resulting in lower value compared to new equipment over 10 years. Ensured new equipment layout would allow for minimal change in surrounding equipment and allow access for maintenance.

Identified and addressed galling on nickel-plated copper battery terminals, implementing a deburring process to improve quality.

Utilized statistical analysis and Six Sigma principles to improve root cause analysis and continuous improvement of main ship battery cells.

Streamlined the creation of Parts Manufacture Approval (PMA) documentation for the Federal Aviation Authority (FAA) by leveraging existing Aero Design documentation.

Hibiscus Essentials LLC. September 2018 to August 2019 Nashville, TN

Owner/Manufacturing Engineer (beverage manufacturing + project management)

Developed comprehensive business plan encompassing market research, recipe development, brewing processes, cost analysis, packaging, marketing, and distribution for local beverage production.

Established valuable networks within the beverage manufacturing industry, collaborating with experts, scientists, sales representatives, and business owners.

Innovated by designing and implementing automated manufacturing controls for cold brew tea, reducing labor costs and human supervision requirements. The automation was semi-automatic and incorporated a pneumatic control system via an Arduino, several valves, sensors, and a camera to allow remote control of water fill for tea steeping, filtration, and carbonation as well as sampling at various stages of the processes to ensure quality control.

Managed documentation for shelf life and quality control, delegating tasks to food testing laboratories and applying project management techniques in a startup environment.

Jacobs Technology July 2015 to August 2018

Tullahoma, TN

Mechanical Engineer I (Machine Designer + Thermal Fluid Systems)

Participated in on-site commissioning of wind tunnel testing equipment. This included considering weight of piece parts components as well as adding removable safety design elements for installation to comply with OSHA requirements. Provided significant cost savings by convincing management to purchase and train engineers on laser measurement equipment instead of hiring an outside contractor.

Andres Garcia

Designed a flexible nozzle mechanism located upstream of the test article which uses electromechanical actuators with DC motors and kinematic linkages in addition to sensor feedback to precisely move the side walls and ceiling inward to create a smaller flow area for high-speed testing. Verified compliance to desired airline profile via ANSYS structural & thermal analysis. Investigated loads into concrete outer structure and implemented appropriate vibration transmission mitigation design to reduce cracking and limit flexible wall motion during high speed testing. Exported 3D shape and overlayed over theoretical shape to meet customer error criteria.

Developed a 3D modular flexible nozzle and flexible floor master part, enabling quick modifications for new wind tunnels via an Excel spreadsheet, resulting in significant cost savings for future projects and allowing for acoustic testing capability with minimal design investment.

Verified flexible floor pneumatic actuators capability to hold airline shape during testing/thermal fluctuations via calculations and FEA analysis including vibration transmission and estimated dampting. Contributed to the fabrication, assembly, and installation drawings of flexible nozzle and floor components, collaborating closely with designers to develop BOM and select appropriate COTS components.

Designed a prototype turbulence generation system (TGS) using AC electrical motors, keyless bushings, planetary gearbox, carbon fiber wings, and kinematic linkages for non-traditional transient testing (turbulent flow wind tunnel testing).

Reduced risk and increased confidence in NASA OME rocket diffuser design by adhering to ASME Boiler Pressure Vessel Code (BPVC). Verified designed test cycles based on fatigue criteria and fatigue stress strain material properties.

Reduced manufacture and testing cost of diffuser and supporting test components by creating 3D models and simulations of rocket diffuser, support frame weldment, and fiberglass vacuum lid. Ensured compliance to appropriate structural/fatigue/stiffness requirements from test components via hand calculations that were refined with detailed FEA models to allow for welded joints/bolted joint load extractions, principal normal stresses in main frame members, and non-linear composite models with layer resolution for fiberglass lid to ensure resin loading was below delamination stress. Collaborated with designers to produce 2D fabrication, assembly, and installation drawings including a bill of materials. Ensured compliance to drawings and functional requirements.

Managed CNC fabrication of proprietary wheel force transducers used for simulating ground forces into the vehicle. Delivered assembled sensors on time, under budget, and within specifications. CERTIFICATIONS & TRAININGS

Engineer in Training – Pursuing professional licensure, planning to sit for PE in Spring 2025

General Dimensioning & Tolerancing – ASME Y14.5 trained DEVELOPED SOFTWARE SKILLS CHARACTER QUALITIES

REFERENCES

NX/Unigraphics – Proficient

Solidworks – Expert

Creo/PTC – Proficient

Inventor – Expert

Revit – Competent

AutoCAD - Proficient

ANSYS – Proficient

Python – Competent

Abaqus – Proficient

MathCAD – Proficient

MATLAB – Proficient

Accountable

Analytical

Adaptable

Communicative

Knowledgeable

Andres Garcia

Leo Benetti-Longhini – Line Manager at Jacobs - 931-***-**** – ***.*******-********@******.***

Tim Whitehead – Colleague at Jacobs – 205-***-**** – *********.*.*@*****.***

Pike Saunders – Project Manager at Jacobs – 931-***-**** – ****.********@******.***

Rich Solbrig – Line Manager at Aero Design – (678) 313 – 6907 - ********@***********.***

Durai Perumal – Line/Project Manager at Wabtec – 631-***-**** – *****.*******@******.***

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