Engineer Design

David Blackburn Home: 818-***-****

**** ********* **. ******: 310-***-****

Agoura, CA 91301 ***********@**.***

Career Profile:

Experienced design engineer and technical lead, with a proven track record of meeting development, qualification, and production goals for the aerospace and automotive industries.

Skills:

Advanced Surfacing (Class A)

Advanced Composite Design

Automated Composite Manufacturing

Design for Manufacturing

Manufacturing Process Development

FiberSim (6000+hrs)

CATIA Composite Workbench (3000+hrs)

CATIA V5 R5-19 (12,000+hrs)

CATIA V4 R1.7-2.4 (10,000+hrs)

Pro-Engineer Wildfire 1.0-2.0 (4000+hrs)

Unigraphics V18-NX7 (8000+hrs)

ENOVIA VPLM

ENOVIA SmarTeam

Teamcenter

Employment:

Space Exploration Technologies, Los Angeles, California 1/11-Present.

Composite Structural Design Engineer:

Lead efforts to transition composite structures manufacturing from development to production.

Lead composites design reviews to ensure laminate designs are producible and feasible for production.

Create flat patterns and laser projection data for production of composite structures using FiberSim.

Create and implement lay-up work order instructions for composites production.

Perform trade studies and cost benefit analysis for automated manufacturing processes and equipment.

HITCO Carbon Composites, Gardena, California 1/09-12/10.

Lead Process Engineer:

Lead engineer for JSF Wing Skin and Nacelle NDI Standards design and fabrication.

Lead engineer for Boeing 787 WP12-15 NDI Standards design and fabrication.

Responsible for qualification and programming of Automated Fiber Placement machinery.

Create, test, and maintain FiberSim / ACE datasets for JSF Nacelle production.

Create surface data for re-machining of JSF Nacelle AFP mandrel, per customer print, using CATIA.

Honda Research and Development, Torrance, California 7/08-12/08.

Lead Engineer / Liaison:

Create interior and exterior Class A surface data for production using CATIA V5.

Create packaging studies according to program guidelines and specifications.

Responsible for creating engineering data packages for release using ENOVIA V5.

Complete packaging objectives for data modeling group as prescribed by engineering.

Liaison between engineering and studio groups; create data packages for release.

HITCO Carbon Composites, Gardena, California 1/08-7/08.

Lead Process Engineer:

Use CATIA V5 and FiberSim to create manufacturing data for JSF and 787 programs.

Lead engineer for Boeing 787 Work Packages 12 & 13 NDI Standards qualification per BAC 5578.

Design tooling and fixtures for automated composites production using ATL and AFP.

Provide manufacturing data across multiple programs for AFP production using CATIA and ACE.

Perform design of experiment and process trials to determine process requirements for production.

Honeywell Turbo Technologies, Torrance, California 8/06-12/07.

Lead Design Engineer:

Provide engine packaging and engineering support for new and existing turbo products.

Create blade surfaces for compressor and turbine wheels using Fluent point cloud data.

Design compressor and turbine castings using customer engine packaging data.

Manage data for racing and passenger vehicle programs using ENOVIA SmarTeam and CATIA V5.

Serve as project lead interfacing between customer engineering and manufacturing groups.

Airborne Technologies, Camarillo, California 8/05-8/06.

Lead Project Engineer:

Provide design and engineering support for C-130 and F-15 spares programs.

Create ML loft surfaces for C-130 forward fuselage and canopy using LMCO supplied V4 data.

Design tooling for structures and skins in accordance with LMCO tool design specifications

Lead a team of 5 engineers in creating production tooling for 60 loft derived structural parts.

Arrowhead Products, Los Alamitos, California 2/05-8/05.

Lead Engineer:

Lead engineer for build to print customer projects involving CATIA (Boeing, LMCO, and NGC).

Create production surface models for drop hammer tooling using customer-supplied data sets.

Lead teams of five to ten engineers and tool designers in creating CATIA data for production.

Develop surface models of compound curvature exhaust ducting for turbine-powered craft.

Volvo Monitoring and Concept Center, Camarillo, California 1/04-2/05.

Studio Engineer:

Create Class A surfaces for production vehicles from conceptual data using CATIA V5.

Create Body In White packaging models for engineering feasibility studies.

Design packaging models for engine and engine components of production vehicles.

Prepare master surface models for NC manufacture of production tooling.

Swift Engineering Inc, San Clemente, California 6/02-1/04.

Studio Engineer:

Create Class A surface models for passenger and racing vehicles using Pro-Engineer Wildfire.

Develop OML / IML loft surfaces for UAV wind tunnel models using CFD data.

Design composite structural fuselage bodies for NGC Unmanned Aerial Vehicle programs.

Create manufacturing data for UAV fuselage lamination, cure and trim using FiberSim.

Perform process trials, destructive / non-destructive test validation of composite structures.

Trans FX / General Motors 5150 Studio, North Hollywood, California 6/99-6/02.

Studio Engineer:

Create Class A body panel surfaces from point cloud using Unigraphics.

Design Interior seating and restraint systems for concept and production vehicles.

Create surface models for door closeouts and sealing arrangements.

Design hard trim interior components from 2D Alias drawings and applicable standards.

Honda Research and Development, Torrance, California 2/98-6/99.

Studio Engineer / CNC Programmer:

Create exterior Class A surfaces from clay model scan and Alias data using CATIA V4.

Create Body In White packaging models according to program guidelines.

Design interior hard trim components and panels from Alias 2D drawings.

Program CNC tool path for prototype body panel and glass tooling.

Dangar Engineering, Newbury Park, California 5/95-2/98.

CATIA Designer / CNC Programmer:

Responsible for recreating customer surface models for CNC production using CATIA V4.

Create Class A surface models and associated CNC code for automotive customers.

Design check fixtures and establish CMM criteria for Pilkington canopy production.

Create 5-axis programming for production machining of large-scale airframe components.

Education & Training:

Bachelor of Science – Mechanical Engineering

Cooper Union, New York, New York

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