- Active Top Secret Security Clearance
- Project Management:
o Organizational skills, budget management, schedule and resource management, production management, task management, risk management track deliverables, set priorities, present status to customer and project managers, interpersonal and communication skills
o PMP Certified
o Software: MS Project
- Mechanical Systems Engineering
o Requirements and specifications flow-down, verification and validation of requirements, hardware delivery certification, design reviews
o Risk analysis, system FMECA, fault tree analysis, fishbone diagrams, non-conformance resolution
o Technical leadership of multi-disciplinary teams
o Software: Telelogic DOORS
- Mechanical Engineering Design:
o Licensed Professional Engineer
o Lead design team, conceptual design, detailed design, prototypes, proof loading, flight qualification, supply chain management, drafting, drawing release, ANSI Y14.1 drawings, ANSI Y14.5 Geometric Dimensioning and Tolerancing (GD&T)
o Spacecraft structures
o Underwater assemblies
o Stress analysis using both finite element analysis and hand calculations
o Software: Solidworks, Unigraphics NX, Ideas, NASTRAN, Mathcad, Matlab
- Composite Structures and Manufacturing:
o Composite Structures: Carbon-carbon composites, sandwich panels, laminates, thermal design, mechanical testing and allowables
o Manufacturing Processes: Autoclave cure, vacuum cure, co-cured structures, potting and injection, 5-axis laser machining
o Tooling Design: Machining of critical tool interfaces, location of hardware lacking convenient features
o Inspection Processes: Ultrasonic inspection, X-ray, neutron radiography, flash thermography
o Materials: 1-part and 2-part epoxy, aluminum and nomex honeycomb, aerogel, carbon fiber, carbon-carbon, silica insulation & thermal protection systems
Job Title: Deputy Delivery (Project) Manager for proprietary active mirror project
o Completed thermal and dynamic qualification program successfully, on time.
o Coordinated qualification program between JPL and 2 subcontractors performing the analysis, construction, and testing of the qualification mirror assembly.
o Managed novel in-house pyroshock test achieving shock accelerations simultaneously on 3 axes with just 1 axis of excitation. Managed work of 2 engineers plus test lab staff to execute this test.
Job Title: System Engineer for Nuclear Power Source for Mars Rover
o Completed verification, documentation and final acceptance of plutonium-fueled Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) for the Mars Science Laboratory mission.
o Coordinated final acceptance review for the high-profile handoff of the nuclear MMRTG from DOE to NASA at Kennedy Space Center
o Led multi-disciplinary tiger-team of subject matter experts to address mission-critical power anomalies
o Managed planning, execution, and completion of power system verification test under pyroshock conditions with team members from 2 subcontractors and 1 DOE lab. Task included status reporting and reviews with project management, JPL Director, and NASA Deputy Director.
o Resolved complex multi-disciplinary non-conformances requiring mission assurance, safety, and project approvals.
Job Title: Production Manager for Electrical Cable Assemblies
o Stepped in to take on management of an underperforming million-dollar task
o Made the cost and schedule plans, and delivered ahead of schedule and under budget
o Managed daily production priorities for delivery of more than 600 unique mission-critical cable assemblies
Job Title: Mechanical Systems Engineer
o Verified, certified, and delivered 2 major structures to the project for integration.
o Managed and distributed ~1000 technical requirements concerning 8 technical disciplines between 10 element engineers.
o Created and managed 29 project Verification and Validation plans and Verification Matrices for verification of the complete structural system per requirements.
o Managed and successfully completed proof test of 2 very large complex composite structures.
o Composed designer staffing plan to level the designer staffing curve for Structures group.
Job Title: Mechanical & Composite Engineer (Mars Science Laboratory Rover Project)
o Member of Rover Structures team designing and building the primary structure for an 800Kg nuclear-powered Mars Rover.
o Lead team that built and delivered flight qualified Rover Heat Exchanger assembly including bonded fluid tubing and composite primary structure.
o Supervised construction, component testing, assembly, and delivery of flight-qualified assembly.
o Managed team of 3 designers and 2 stress analysts from initial concepts to completed detailed design of composite and metallic primary and secondary structures.
o Responsible for managing entire design and manufacturing process from raw material to delivered flight hardware.
o Completed mechanical and thermal materials testing program on sandwich panel components and potted inserts.
o Supervised development of a new process for bonding aerogel inside honeycomb sandwich panel.
o Supervised process development for combined structural and thermal bonding of fluid tubing to surface of contoured composite sandwich panel.
o Created bonding injection process for special potted insert configuration to satisfy through-panel thermal conductivity restrictions.
o Released 66 drawings for construction of primary and secondary structure.
Job Title: Mechanical & Composite Engineer (Nuclear-Electric Xenon Ion Propulsion System)
o Member of competitive research team to develop 57cm ion engine for Prometheus mission to Jupiter’s moons.
o Delivered 2 carbon-carbon composite ion optics assemblies for flight qualification at Delta IV vibration levels.
o Monitored large $656K design and manufacturing effort with 10 vendors in 5 states, including $240K vendor contract for construction of carbon-carbon composite structures.
o Supervised design, drawing release, and manufacturing of spherical carbon-carbon composite ion optics.
o Managed complex manufacturing process and supply chain for production of ion optics assemblies on an aggressive schedule.
o Introduced industry best-practice ultrasonic inspection and 5-axis laser machining techniques into production stream.
o Conceived, demonstrated, and implemented a unique algorithm for locating a hexagonal pattern of holes on a spherical surface and calculating hole location and orientation parameters in CNC coordinates.
Job Title: Mechanical & Composite Engineer (Mars Exploration Rovers)
o Designed tooling for location and bonding of complex composite rover chassis structure.
o Designed tooling for location and bonding of rover composite top deck panel.
o Conducted tolerance study and dimensional inspection of chassis and top deck tooling.
o Wrote procedure for assembly and injection of adhesive into rover chassis assembly.