Mechanical Engineer and Project Manager

Brandon S. Ward

** ************ ****, *******-*****, NC 27104

*************@*****.*** 757-***-****

Professional Summary

Mechanical Engineer and Project Leader with 14+ years of experience in structural certification, R&D, and product development across aerospace and automotive industries. Skilled at leading cross-functional teams, managing certification and development programs, and driving continuous improvement in engineering processes. Hands-on problem solver able to balance technical depth, regulatory compliance, and project objectives.

Core Competencies

• Mechanical Design, R&D, and Prototyping

• Aerospace Structural Certification & Compliance (14 CFR 25.561/25.562, TSO C39c/C127c)

• Structural Static and Dynamic Testing (sled, static, abuse loads, injury criteria)

• FEA, Simulation, Stress Analysis, and Calculations

• Quality Assurance, Root Cause Analysis, and Continuous Improvement

• Project and Program Management (PMP, SAP, APQP)

• Cross-Functional Leadership and Mentorship

• Product Development, Launch, and Manufacturing Transfer

• Lean Methodologies and Process Optimization

Professional Experience

Senior Certification Engineer Collins Aerospace – Winston-Salem, NC Nov 2023 – Present

• Led certification of occupant safety systems (seats, restraints, and structures) in compliance with FAA/EASA requirements including TSO C39c & C127c and 14 CFR 25.561 & 25.562.

• Directed dynamic sled, static load, and abuse load testing to demonstrate compliance with crashworthiness standards and aircraft-specific requirements.

• Prepared and validated test plans, conformity requests, and compliance reports; collaborated closely with FAA DERs and ODA unit members to ensure approval.

• Performed finite element analysis (FEA), simulations, and calculations to support test readiness and correlate analytical models with test results.

• Partnered with design teams to translate regulatory requirements into system-level structural criteria and integration strategies.

• Collaborated with teams of engineers to evaluate and integrate contemporary designs, balancing innovation with certification requirements.

• Supported mechanical design reviews and provided input on structural optimization, material selection, and manufacturability.

• Coordinated test article build and instrumentation with suppliers and external labs to ensure regulatory compliance.

• Authored and reviewed certification documentation packages including compliance matrices, substantiation reports, and test results.

• Mentored junior engineers on certification processes, FAA/EASA compliance, and technical writing best practices.

• Supported process improvement initiatives in crashworthiness workflows, reducing test/report cycle times.

• Assisted production build issue resolution and rework dispositions for certification test articles. Project Manager / Mechanical Engineer Alten Technology – Greensboro, NC Jul 2021 – Oct 2023

• Directed multidisciplinary development of robotic lifting systems, overseeing system architecture, layout, and interface definition across mechanical, electrical, and software domains.

• Established project schedules, budgets, and KPIs while reporting status to internal stakeholders and OEM customers.

• Coordinated prototype builds, integration testing, and design verification using Creo + Windchill, Zuken, and LS-DYNA.

• Designed components and assemblies in sheet metal, CNC-machined steel/aluminum, extrusions, and 3D-printed plastics, applying DFM and optimization principles.

• Led prototyping and experimental validation of optical detection and PID control systems to confirm design intent.

• Organized cross-functional teams for issue resolution, weight reduction, and cost optimization initiatives.

• Built and maintained engineering test workspaces to support prototyping and validation. Project Leader Bocar US – Huntsville, AL Jul 2020 – Jul 2021

• Managed production launch of multiple aluminum high-pressure die cast components for automotive OEMs.

• Conducted PPAP submissions per APQP and customer-specific systems.

• Mitigated schedule, quality, and cost risks through PFMEA and KPI tracking.

• Oversaw multi-million-dollar CapEx and tooling budgets in SAP.

• Drove root cause analysis on casting and dimensional quality issues; implemented corrective actions to reduce porosity and improve process capability. Project Leader KTH Parts – St. Paris, OH Nov 2017 – Jul 2020

• Directed new product introduction (NPI) of nine concurrent Acura TLX assembly lines from design through start of production.

• Managed process development for sheet metal stamping, welding, and structural adhesive application.

• Developed specifications and quality standards for self-piercing rivet assembly, leveraging R&D data to improve process reliability and reduce defects.

• Coordinated customer communication, prototyping, and manufacturing readiness activities. Product Engineer Busch Vacuum Pumps and Systems – Virginia Beach, VA Jul 2012 – Nov 2017

• Designed and tested custom vacuum pumps, managing R&D experiments and data acquisition.

• Created BOMs, specifications, and drawings for new product builds.

• Matched customer requirements to standard and non-standard products including pump configurations, metallurgies, and accessory systems.

• Provided direct customer support, quotations, and field troubleshooting.

• Constructed and maintained a dedicated R&D lab for pump testing and training.

• Trained new engineers and technicians on product lines and project workflows. Education

Bachelor of Science in Mechanical Engineering (BSME) Virginia Tech – Blacksburg, VA May 2011

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