SUMMARY:

• Innovative and comprehensive design engineering and product development
• 3D CAD modeling, drafting, and engineering
• Product evolution and new material R&D
• Precision inspection, analysis, and reverse engineering
• Functional prototype creation, master machinist
• Manufacturing process design and efficiency analysis
• Comprehensive blueprint reading, drafting, and Confidential & Confidential
• Manufacturing team leadership, coordination, and training
• Strong communication skills
• Ability to transform complex concepts into results - driven solutions
• Creative design for micromechanical, industrial, electromechanical, and biomechanical systems
• Materials Science, Polymer Development

TECHNICAL SKILLS:

• 25+ years of experience with ProEngineer, SolidWorks, Alibre Design, Mastercam, and other 3D Modeling and Design Software Tools
• Microsoft Office (Word, Excel, PowerPoint)
• Advanced G-code programming and setup of computer controlled manufacturing equipment, including CNC machine centers
• Ansys Finite Element Analysis

SELECTED WORK EXPERIENCE:

Design and Development Engineer

Confidential, Warminster, PA

Responsibilities:

• Created original designs for elastomeric microelectronic connector systems using Solidworks, and manufactured the prototypes. Applications ranging from MEMS to medical, cellphone to aerospace. Designed and built manufacturing tooling for the automation of production. Coordinated with vendors, clients and the manufacturing team.
• Developed function chemistry for a number of silicone and epoxy based applications. Several of the original part designs and manufacturing processes were new to the industry.
• Developed polymeric substrates involving nanoparticles and chemical functional groups. Electromechanical and MEMS system development using polymer and elastomeric substrates.
• Designed injection molding systems for liquid silicone rubber micro-manufacture of medical apparatus.
• Conceived and developed hardware for the control and application of micro-wire delivery and bonding systems for the manufacture of elastomeric micro-connectors for high tech electronics.
• Managed the equipping of a product development facility including a prototype machine shop with CNC tooling and chemistry lab.
• Trained workers.

Confidential, Willow Grove, PA

Consultant

Responsibilities:

• Re-engineered a field-deployable solar powered water pump and filtration unit for a smaller and lighter frame, created detailed drawings for fabrication in CAD, performed a high wind FEA failure analysis, coordinated fabrication, performed vendor searches, and purchased part and component planning.
• Re-engineered a coffee bagging machine with a design team, performed full assembly and gear box design, performed on site installation and set-up with the client team.
• Performed assembly and testing. Presented weekly updates in online virtual environment with our long distance client showing 3D models and current developments in the project.

Confidential, Pennsauken, NJ

Consultant

Responsibilities:

• Designed and engineered downstream tooling for thermoplastic extrusion machines.
• Drafted old and revised drawings into CAD documents with 3D models in Alibre Design

Confidential, Philadelphia, PA

Consultant

Responsibilities:

• Engineered and drafted using Alibre 3D design, a series of parts and mechanisms for a multi-axis fixturing system for welding applications, and other welding accessories and components.
• Worked with machine shops to facilitate the manufacture of these devices.

Confidential, Philadelphia, PA

Consultant

Responsibilities:

• Evaluated designs and provided manufacturing consulting for cylindrical die technology for sustainable manufacturing applications.
• Designed CAD models of parts using Solidworks.
• Machined parts for the complete automation of an H1 Hummer all terrain desert vehicle, including customization of power and hydraulic systems, drive by wire, and actuator integration.
• Programmed a Fadal 4020 CNC vertical machining center, and Bridgeport-Romi CNC lathe for precision machining.
• Fabricated parts utilizing MIG and TIG welders.
• Mentored 15-20 students, and taught the use and operation of manual and CNC mill and lathe machine tools.

Biomechanical Projects Research Assistant

Confidential, Philadelphia, PA

Responsibilities:

• Designed CAD models using ProEngineer for the creation of a series of mechanical characterization and testing devices.
• Designed, machined, and built the testing equipment for a series of micro-mechanical studies of cell walls of drought resistant plants.
• Developed operating protocols for said tensile testing apparatus.
• Developed imaging protocols for biological samples using an atomic force microscope, and codified a method for histochemical analysis of structural compounds within the cell wall.
• Mentored students in the design and development of research and engineering projects.
• Co-wrote several scientific papers and book chapters, which were published in peer-reviewed engineering/science academic journals.
• Conceived, designed, and manufactured equipment and fixtures for characterizing the bending and buckling mechanics of carbon nano-tubes using a nano-indenting machine, an electron microscope and a nano-manipulator.