Senior Level Mechanical Design Engineer

If you are interested in this talent, please call  256-881-5724

SUMMARY

I am a self-motivated and innovative Mechanical Design Engineer with demonstrated ability in using Pro/E and Pro/M.  With 12,000+ hours experience with Pro/E, 2,000+ hours experience with Pro/M, 9,000+ hours experience with IronCAD, and 2000+ hours experience with Algor, I am competent in providing 3D CAD Models, Detailed Drawings, Materials Selection and Proper Materials Treatment, Stress Analyses, Modal Analyses, Frequency Response Analyses, Finite Element Analyses, and Proof-of-Concept Design.

I am a hands-on engineer with a real understanding of how things work and how they won’t.  I deliver engineering excellence by producing simple, innovative solutions to design challenges.  To ensure completeness and consistency, I approach design from every possible angle.  I then combine, filter, reduce and finally forge the simplest solution with an aim to minimize redundancies, combine feature functions and keep costs and complexity to a minimum.  I am skilled at the art of group and independent brainstorming with an unyielding determination to reach the correct solution.  I have the skills to take a product from conception to a deliverable product.   

I have good oral and written communication skills, with the ability to conduct design presentations to a group of peers. I can work with minimal assistance or as a member of a team.

PROFESSIONAL ACHIEVEMENTS

Co-Inventor:        U.S. Patent #6,412,447 B1  “Fuel-Fired Water Heater with Flammable Vapor Sensor and Associated Induced Flow Tube”

Inventor:       U.S. Patent #6,439,171 B1  "Inner Door/Burner Assembly for Fuel-Fired Water Heater"

Inventor:       U.S. Patent #6,547,558 B2  "Methods of Making a Fuel-Fired Heating Appliance"

Inventor:       U.S. Patent #6,554,610 B2  "Methods for Constructing a Combustion Chamber Access Door and Associated Apparatus"

Pending Co-Inventor: Linear And/Or Curvilinear Rail Mount System  (NASA Patent For Modular Avionics Rail) 

Received a Continuous Improvement Award, 2007 - Creation of Modular Aft Skirt Avionics Mount

Received an Extra Miler Award, 2007 - Exemplary Performance and Dedication in Support of Ares I Crew Launch Upper Stage Structures And Thermal Integrated Product Support

Received a Group Achievement Award, 2008 - Integrated Upper Stage Initial Layout Review

Received an Extra Miler Award, 2008 - Outstanding Effort System Tunnel Layout Review Presentation

Received a Certificate of Appreciation MPP, 2008 - Pro-E Wildfire Mentor Training

Received a Certificate of Appreciation MPP, 2009 - Pro-E Wildfire Mentor Training

Received an Extra Miler Award, 2009 - Significant Contribution to the Ares I Separation Joint Trade Study

Magazine Publication:  Article “Rotary for the Records”, 2002

Magazine Publication:  Machine Design, Article “Big designs in flux? No problem for this CAD”, 2006

Newsletter Publication:  IronCAD Support Newsletter, Article “Customer Spotlight: Company Uses IronCAD to Build Particle Accelerator for Oakridge Labs”, 2007

Advertisement and Publication:  “See How IronCAD and ALGOR Can Help Cut Your Cost per Design!”, 2007

Guest Speaker, Clark University - Physics Department, Atlanta, Georgia, “Education, Engineering Career, and Engineering Tools”, February 2010

Guest Speaker, Georgia Perimeter College - Engineering Department, Atlanta, Georgia, “Education, Engineering Career, and Engineering Tools”, February 2010

COMPUTER EXPERTISE

CAD Programs:             Pro/Engineer V20, 2000i^2, V2001 and WildFire, Pro/Mechanica, IronCad, Algor, Rhinoceros

                                    Familiar with Unigraphics, Solid Edge, Solid Works, Think 3, AutoCAD Inventor

Other Software:             Mathcad, Visio, Microsoft Word, Microsoft Excel, Microsoft Powerpoint, Microsoft Access,                                            Microsoft Project, Microsoft Outlook

PROFESSIONAL EXPERIENCE

NASA – National Aeronautics and Space Administration, Huntsville, Alabama                         5/07 – Present

Mechanical Engineer

Jacobs/ERC Engineering Support Team

Mechanical/Structural Design and Analysis using Pro/E WildFire, Pro/Mechanica, IronCAD, and Algor

Ares 5 Structural Design Group:  Task lead for Ares 5 over the Vehicle Integration, Core Stage and Solid Rocket Booster design and support functions.   Responsible for schedule deliverables, end of phase cycle  PA-C reports, presentations to the NASA customer, task order revisions, monthly activity reports, and yearly reports to NASA customers and Jacobs management.  Designed new internal ring framing support structure for forward skirt to allow better distribution of increased SRB (Solid Rocket Booster) loads through skirt structure and forward skirt extension.  Designed internal ladder system to be used by ground support for easier access to SRB avionics and support systems within forward skirt.  Designed new safe and arm device layout routing to allow remote pyro activation or deactivation of safe and arm device of SRB.  Designed new forward skirt separation motor structural framing and location that would allow separation motors to be contained within the forward skirt and reduce the profile and number of protuberances on the outer mold line of the SRBs while still maintaining a design that would allow the most effective thrust direction towards the core stage.  Designed the separation motor structural pods that would hold all the necessary pyrotechnic and control components for the separation motor functions.  Created SRB separation animations to show the separation path of the SRB during flight and to demonstrate margins, or how close the SRB passes to the core stage in order to help the aero group facilitate a study and brain storming sessions of how to correct or increase margins during separation to prevent SRB contact with core stage.  Designed and modified the SRB parachute system based on the Ares 1 and Shuttle heritage parachuting systems to contain a larger parachute system to hold the 5 segment SRB and the required deployment system all to be contained within the same shuttle heritage 4 segment SRB nosecone.  Wrote report for the PA-C3 design cycle to be presented to the NASA customer demonstrating the design work performed for the SRB subtask.

•  Ares 1 Lox Tank Group 
•  Ares 1 Thrust Oscillation Group

 Ares 1 Upper Stage Team:  Completed test assembly to assist in determining how the production release method and DDMS EPL generation functions will work.  Worked with Aft Skirt group on the top down assembly method and remodeling various structural components.  Coordinated a meeting with a Pro-E consultant group used by SNS at Oak Ridge National Laboratories, Oak Ridge, Tennessee to provide an alternative Top Down Modeling method that would increase our productivity without compromising the work already completed and would be an easier system to adopt and merge into current modeling method.  Provided assistance to various members on the Upper Stage team as needed to solve minor CAD / ProE related issues.

Ares 1 Pyro Group:  Responsible for re-modeling Pyro components from the System Tunnel assembly to the correct dimensions.  Completed model and re-model of all currently available Pyro components.  Conceptualized and designed a dual plane separation joint to separate the upper stage and solid booster first stage that replaced the previous tension ring separation system and allows Pyro to cut through primary load carrying structure.  This new concept is an improvement since the previous design had problems with separation reliability, weight, real estate, aero heating, and protection of the separation Pyro system.   This new concept was the first Ares separation ring design that had yielded positive stress margins thus making it a design that ensured project success and is a component critical to mission success.  Designed custom manifolds for the FCDC initiators in the new separation ring configuration.  Designed features into the separation system that will catch or deflect the resulting pyro/cutting debris; this shielding system will be critical to the protection of the avionics system, flight control systems and the J2-X engine from the resulting cutting debris and shock from the pyrotechnics separating the stages.   Designed compression pads that will carry the compressive loads throughout the entire flight up until separation, and then will carry any compressive loads to prevent re-contact of the after separation joint is fired.  Designed new version of the separation joint which removed the staggered separation plane and allowed the sep system charge to fire and cut the structure in one plane.  Presented new dual load path sep joint design to Pyro Team and trade study review board. The new modifications allowed us to drop core load from 55 gpf to 30 gpf.    Presented the final LSC sep joint designs to the Engineering Change Board and Engineering Review Boards.  Created rubber isolation concepts for shock mitigation efforts to better protect avionics electronics, ullage motor pods, and roll control systems.  Designed an aero shield to protect the Frangible Joint separation system from ullage plume impingement and aero heating and to offer additional protection during upper stage assembly.  Created Ares1 A105 Pyrotechnics Configuration poster that became official pyrotechnics information poster for the entire upper stage team.

•  Ares 1 Aft Skirt Group
• Ares 1 Systems Tunnel: 
• Utility/Avionics Rail System
• FIP System Tunnel Concept

JACOBS / ERC General Engineering Support Work:  CAD geometry cleanup, simplification and geometry healing for the Ares 1 and Ares 5 analysis groups.  Healed, cleaned and simplified 3D CAD geometry for Aero Group, Thermal Analysis Group, and Structural Stress Group.  Provided 2D geometry simplified profiles to Aero Group, Thermal Analysis Group, and Structural Stress Group.  Provided this service to be used in different analysis packages such as Algor, FEMAP, PATRAN, Pro-E Mechanica and MSC NASTRAN.  Created simulation and functional animations for Ares 1 and Ares 5 of various systems such as SRB separation events, sep motor pod separations and pyrotechnic stage separation events.  Created simulated installation animations for component assemblies such as Avionics Box installations.  Created process animations to demonstrate order of assembly and manufacturing steps.

MULTIPLE DISCIPLINE TECHNOLOGY GROUP, LLC, Huntsville, AL                                                    3/01 – Present

Project Engineer, President/Owner

ORNL – Spallation Neutron Source, Oak Ridge, Tennessee,  Instrument Engineer, 8/04 – 5/07.

• Mechanical/Structural Design and Analysis using Pro/E WildFire, Pro/Mechanica, IronCAD, and Algor
• Small-Angle Neutron Scattering Diffractometer – BL 6
• Powder Diffractometer (POWGEN) – BL 11A
• High-Resolution Chopper Spectrometer (SEQUOIA) – BL 17
• Wide-Angle Chopper Spectrometer (ARCS) – BL 18
• Chopper Group

PECOS, INC, Oak Ridge, Tennessee

• Mechanical/Structural Design and Analysis using IronCAD, Algor, Rhinoceros

 Conceptualized, designed and performed analysis for a HYSPEC, a direct geometry spectrometer to be built on a beamline at the Spallation Neutron Source (SNS).  The HYSPEC T2 Chopper is a straight-slotted Fermi chopper.  Installed at the downstream end of the primary HYSPEC spectrometer neutron guide, the T2 Chopper Assembly’s function is to define the energy and burst width of the neutrons incident on the sample.  It is specifically intended as a high intensity, medium resolution instrument for the measurement of excitations in small single crystal samples.  Four choppers and a focusing crystal condition the incident beam on HYSPEC.  The choppers T0, T1A and T1B are used to remove unwanted contaminant neutrons from the beam while the chopper T2 is used to define the energy width and burst time of the neutron pulse incident on the sample.

Analyzed the design for strength and natural frequency in multiple analysis sequences to ensure the housing would operate under rotational loads in integral multiples of the (60 Hz) source frequency.

Analyzed the rotor cavity to ensure it would withstand the combined loading of the centrifugal forces, vacuum forces and forces exerted by the slit package assembly.

Analyzed the glass pack to ensure it would withstand the loading and deflection under the specified conditions.

Additional requirements were that the rotor/containment-vessel assembly be easily removable from the drum shield and so-designed as to permit precise and reproducible replacement in its original position.

Designed the rotor such that the rotor/containment-vessel assembly allowed for easy and rapid exchange of slit insert packages.

Designed to meet remote handling requirements because the assembly will become activated and was designed to minimize personnel radiation exposure associated with maintenance and with changing slit packages.

Material iterations were analyzed with non-magnetic materials with corrosion resistance and small neutron activation cross-sections.

Young Touchstone, Jackson, Tennessee

• Mechanical/Structural Design and Analysis using IronCAD, Algor, and Rhinoceros
• Converted Cad models by creating suitable step files of the geometry from UG format, taking measurements, and Cad geometry cleanup for CNC equipment preparation and manufacturing of heat exchanger ducting for Young Touchstone, Jackson, Tennessee

The Options Group, Montgomery, Alabama

• ·          Mechanical/Structural Design and Analysis using IronCAD and Algor

Dealeo, LLC, Duluth, Georgia

• ·          Mechanical/Structural Design and Analysis using IronCAD and Algor

PAR 3 Vision, Duluth, Georgia

• ·          Mechanical/Structural Design and Analysis using IronCAD and Algor

MagnaCad Design, Inc., Commack, New York

• ·          Mechanical/Structural Design and Analysis using IronCAD and Algor

MAYTAG COMPANY, Washer Group, Searcy, AR                                                                                 4/04 – 6/04

Mechanical Engineer                                                                     

• ·          Mechanical/Structural Design using Pro/E

DEVILBISS AIR POWER COMPANY, Pressure Washer Group, Jackson, TN                                         8/02 – 4/04

Mechanical Engineer   

Mechanical/Structural Design and Analysis using Pro/E WildFire, Pro/Mechanica, and IronCAD

 Conceptualized and designed several plastic attachments and enhancing tools for the pressure washer

 Designed plastic components to enhance the look and/or replace metal components

Designed plastic motor and pump shrouds to meet UL approval and protect both the pressure washer components and users

 Designed steel tubing frames and sheet metal mounting plates

• Designed the layout and configuration for mounting the pressure washer components and various attachments
• Designed a new and less restrictive plastic poppet valve cage to reduce cavitation
• Conceptualized and designed several snap-together frame designs to reduce cost and examined faster assembly and alternative fastening and welding methods
• Conceptualized and designed a cart bolt-on attachment “mobility base” to enhance consumer use
• Researched alternative materials and coatings to reduce the cost and weight of existing pump pistons while reducing friction and increasing pump life and mechanical efficience        
• Researched alternative sealing methods to adapt and allow gear and vane type pump designs to achieve pressures of 1600 to 4000 psi
• Redesigned castings to reduce cost and part count by incorporating several features into the casting    
• Assisted in the layout, development and engineering of a new one-cylinder pump casting
• Designed the drive mechanism, bearings and poppet valve/plumbing layout, pressure unloader, and pump head for the new one-cylinder pump
• Initiated, conceptualized and designed a more aesthetically pleasing protective shroud for the new one-cylinder pump

RHEEM MANUFACTURING COMPANY, R&D Department, Montgomery, AL                                          3/99 – 8/02

Mechanical Engineer

Mechanical/Structural Design using Pro/E

 Team member on design team to redesign the entire residential gas product line.  Redesigned the inner combustion chamber door assembly insuring an airtight seal to guard against flammable vapors, making online assembly and testing faster, and making future field modifications and serviceability possible without disturbing the chamber seal.  Worked with suppliers to obtain parts and address design issues.  Regularly participated in team meetings to discuss the progress of the project and resolve design issues.  Worked with lab technicians to test design concepts

 Performed life cycle testing on various silicone foams, solid silicones, rubber compounds and ceramics using an environmental chamber that simulates the internal and external water heater operating environments of temperature and humidity in search of the proper gasket material that would achieve the goal of both surviving the necessary environment and be durable enough to sustain field service abuse

 Redesigned the entire residential gas product line outer door assembly, which incorporated the use of a tip-out window with a reflective surface to achieve a more aesthetically pleasing design while functioning as a means to view the combustion chamber while lighting the water heater

Team member on design team to redesign the electric and gas to reduce costs.  Responsible for a number of projects to design for use of common components across the product line to reduce the number of parts, reduce tooling, reduce part costs, and reduce the complexity of assembly through the use of consolidated sub-assembly designs and alternative fastening / snap-fit designs for both plastic and metal materials.  Responsible for consolidating the jacket design to allow for only one foaming operation, replacing the current foam insulation process requiring multiple components and stages

Performed water heater element and anode rod life testing to determine the overall life of the elements in differing water conditions and the anode rod’s effectiveness in providing corrosion protection

Ÿ  Established test procedures, reports and specifications for both gas and electric water heaters covering all aspects such as technical, environmental, and packaging.  Established burn test and evaluation procedures.  Performed plastics testing and degradation analyses.  Established paint and substrate coating specifications

Worked with professors at various local universities on projects ranging from analyzing and solving causes of premature heater element failures to finding improved salt-spray resistant coatings and paints

RAYTHEON SYSTEMS COMPANY, Mechanical Design Dept., Greenville, TX                           2/97 – 3/99

Mechanical Engineer

Mechanical/Structural Design using Unigraphics

Designed electrical enclosures, which required knowledge of manufacturing processes to make use of aluminum sheet metal and milled parts (various tasks included creating features such as flanges, bent tabs, bend reliefs, etc., and fabricating specialized parts)

Designed enclosures to be cost effective, long lasting and easy to assemble while keeping in perspective other design constraints such as ventilation, weight, size, EMI shielding, either forced air or natural convection cooling, maintenance and manufacturability

Fully documented designs from proposal to completion per ISO requirements, F.A.A. requirements and military/private customer requests

Updated designs by doing various machine shop tasks (drilling, milling, etc.)

Designed cable routing by producing detailed point-to-point interconnection wire lists and cable drawings from schematics

Assisted in the supervision of pilot assembly workers in the assembly of electrical enclosures during the first article assembly by acting as liaison between engineers and assemblers, and checking product drawing documentation

Coordinated visual sell-off with QAC and customers of electronic enclosures

Performed Test Engineer duties by overseeing the environmental testing of enclosures to military specifications for vibration, shock, temperature, altitude, and humidity.  Responsible for the coordination of corrective actions in the event of enclosure failure (electrical or mechanical).

Wrote environmental test procedures for individual enclosure designs to meet F.A.A. and customer requirements for vibration, shock, and a seventy-seven hour temperature, altitude and humidity test

 Served as Jr. Departmental Specialist on a Continuous Process Improvement (C.P.I.) team to research design improvements in electromagnetic shielding for electronic enclosures

GEORGIA PACIFIC, Preventive Maintenance Dept., Cedar Springs, GA                                                1/95 – 3/96

Co-Op, Mechanical Engineer

Assisted in data collection for vibration analysis and preventive maintenance

Responsible for reports on equipment conditions within the mill, visual inspections, interpretation of vibration data and decisions on corrective measures

 Used AutoCAD for revising old drawings and creating new and more detailed drawings dealing with electrical and mechanical equipment, programmable logic controller routes, piping routes and electrical circuits

Assisted millwright mechanics in equipment installations, alignments, change outs, shutdowns, startup procedures, lockout safety procedures and other repairs

 Learned the workings of various equipment such as pumps, air compressors, gear boxes, chain and belt drive systems, hydraulic pumps, oiling/lubrication systems for paper machines, power transmission couplings (rigid, flexible, fluid, magnetic, offset), bearings, pipe valves, steam turbines, fire/water tube boilers, electric motors and variable frequency drives

OTHER EXPERIENCE

Experience with shop equipment:  metal lathes, milling machines, and other shop equipment in which detailed machining is made according to specified dimensions

Machining setup and preparation with knowledge of tramming, tooling setup, and alignment

CNC milling tool path generation, CNC setup, prototyping

Eighteen (18) hours training on milling machines and machine shop safety

Rapid prototyping using Z-corp 3D printing machines

Perform minor electronic repairs which require the use of multimeters and soldering equipment

EDUCATION

Masters of Business Administration, Auburn University of Montgomery, August 2001

Bachelor of Mechanical Engineering, Auburn University, December 1996

Successfully passed the Fundamentals of Engineering Exam, April 1997

VOLUNTEER WORK

 Volunteer design engineer for F.I.R.S.T. (For Inspiration and Recognition of Science and Technology), a program introducing high school students to engineering fundamentals and the design process in preparation for a nationwide robotics competition.  Tasks performed included assisting high school students in robotics mechanism, chassis and motion design, IC board preparation and assembly, IC preparation, wave soldering, and various machine shop functions.

Gave presentation of CAD design work on Ares project to the Coffee County Central High School students.  A broad range of topics were covered with main emphasis on Engineering, Computer Aided Design, college and working world experience.

Participated in Jacobs Engineering Mentor/Peer Program teaching ProE/Wildfire.

 Jacobs Engineering new hire sponsor for Ares I.