President

• Jun 2018 - Present

Product design and engineering services. If you’re an inventor with a new idea, a startup company ready to turn your prototype into a polished product, or an established business needing extra assistance, Carver Design Group is here to help move things forward. We have the expertise and drive to take your design projects to the next level. We combine our real-world production experience with a passion for cutting-edge design to ensure profitable products. Product design and engineering services. If you’re an inventor with a new idea, a startup company ready to turn your prototype into a polished product, or an established business needing extra assistance, Carver Design Group is here to help move things forward. We have the expertise and drive to take your design projects to the next level. We combine our real-world production experience with a passion for cutting-edge design to ensure profitable products.

General Manager

• Apr 2022 - Nov 2022

Principal Engineer

• May 2019 - Apr 2022

Design Engineer

• Apr 2016 - Nov 2018

• Exercised complete responsibility for new equipment projects including research, budgeting, design, procurement, testing, production, and quality control. • Designed precision machined, laser-welded, and injection-molded components for high-performance liquid chromatography (HPLC) systems. • Worked extensively with outside suppliers to quote and supply components. • Defined quality specifications using geometric dimensioning and tolerancing (GD&T). Wrote programs for automated vision inspection system. • Addressed quality concerns relating to legacy products. Updated existing products for improved functionality and reduced cost. • Implemented a 3D printing system to reduce product development time. • Served as SolidWorks CAD system administrator and resource for design and manufacturing. • Developed an automated system linking QC-Calc inspection software with an SQL database. • Designed and built custom test equipment and production fixtures, using machine tools as needed. Show less

Owner

• Jul 2005 - Jul 2018

• Provided design consultation services for products and custom equipment. Extensive use of complex 3D surfacing, machined components, sheet metal, and injection molding. • Designed, procured, and shipped machined, injection-molded, extruded, and sheet metal components. • Utilized engineering and business principles to build and operate multiple e-commerce platforms. • Operated "Top Gear Outfitters" sales channel on Amazon.com. • Programmed automated inventory, logistics, and shipping systems utilizing MySQL. • Built processing and shipping facilities based on industrial engineering principles. • Developed feedback-based marketing models to optimize sales and profitability. Show less

Sr. Mechanical Engineer

• Mar 2003 - Aug 2006

• Developed electromechanical computer disc publishing systems from concept through design,prototyping, testing, and manufacturing. • Co-inventor of U.S. Patent # 7,311,367 for the apparatus and methods of sensing and clamping discs. • Implemented the use of Geometric Dimensioning and Tolerancing standards. • Designed and procured injection-molded, sheet metal, and machined components to meet mass production requirements. • Launched a rapid prototyping fused deposition modeling system, significantly decreasing product development time and cost. • Served as CAD administrator, implementing Pro/ENGINEER Wildfire & Intralink. • Supported legacy products. Improved system quality while decreasing material and assembly costs. Show less

Senior Mechanical Engineer

• Apr 2002 - Dec 2002

• Designed and documented robotic material handling systems integrated with vision inspection and sub-micron servo alignment for the flat panel display and semiconductor industries. • Designed clean room enclosures and air handling systems. • Consulted with customers to specify system requirements. • Selected and directed vendors for machined and sheet metal components. • Directed assembly technicians. • Designed and documented robotic material handling systems integrated with vision inspection and sub-micron servo alignment for the flat panel display and semiconductor industries. • Designed clean room enclosures and air handling systems. • Consulted with customers to specify system requirements. • Selected and directed vendors for machined and sheet metal components. • Directed assembly technicians.

Design Engineer

• Sep 2000 - Jan 2002

• Designed and documented automated high-speed, high-precision, multi-axis process and metrology equipment for the telecommunication and data storage industries. • Designed low profile linear motor stages with acceleration capability of 1.5 g and positional repeatability of 5 microns. • Developed a rotary servo stage with 360,000 count per revolution accuracy and total runout of less than 0.0005 in. Reduced design complexity, decreased part count, and reduced cost by more that 50% from the previous design. • Modeled, analyzed, and optimized flexure designs for the edge gripping of 1 mm glass parts with 50 micron positional tolerance and angle variation of 0.15°. • Guided technicians in product assembly and testing. • Identified and qualified external vendors. • Served as SolidWorks CAD administrator. Show less

Senior Mechanical Engineer

• Aug 1995 - Aug 2000

• Researched, designed, and developed proprietary process equipment for the mass production and packaging of toothbrushes and dental accessories. • Implemented the use of six seats of SolidWorks for the department. Served as a resource for other engineers regarding SolidWorks design practices. • Selected and used Working Model software to simulate virtual systems before physical prototyping. • Managed the integration of over $10MM of robotics, vision inspection, molding, and packaging equipment for the automated production of the CrossAction toothbrush. • Performed the facilities layout of a $5MM building expansion. • Consulted with research and design group for the development of the CrossAction toothbrush. • Conducted process research and development for toothbrush manufacturing systems. • Designed, simulated, and built high volume production and packaging equipment. • Managed system build, installation, and implementation. • Headed laboratory testing program. • Researched and implemented CAD and CAE systems. • Integrated departmental usage of geometric dimensioning and tolerancing standards. • Performed manufacturing equipment modification design using Cadkey software. • Provided molding, assembly, material handling, and packaging process improvements. • Specified process equipment and coordinated installation for toothbrush bristling operations. • Implemented statistical process control and design of experiments to document process improvements. • Utilized high-speed video system to improved bristle trimming operations. • Modernized interdental bristling department with advanced product transfer system. • Wrote technical operation and service manuals. Show less

Manufacturing Engineer

• Aug 1991 - Aug 1995

• Managed automated aluminum machining systems installations, maintenance, and modifications. • Designed and implemented machining equipment modifications. • Coordinated production quality control and gauging procedures. • Served as production quality interface with suppliers and customers. • Consulted with product design staff. • Held positions of cost savings team leader, ISO-9000 internal auditor, and ergonomics committee member. • Oversaw the implementation of six leak detection systems worth $0.5MM each. • Directed mass spectrometer helium leak testing upgrade and maintenance program. • Coordinated $2MM improvement project in the area of final inspection and packaging. • Specified and implemented gauging and flow test equipment. • Served as quality liason to Norfolk, VA truck assembly plant. • Performed production scheduling. • Developed tracking system for vacuum brazing production and maintenance. • Supervised operation and maintenance of vacuum brazing furnaces. Show less