Senior Mechanical Designer

• Jun 2020 - Present

Drive end-to-end 6-month development of IBUC RF components to bring advanced performance and features to C-band, X-band, Ku-band, and Ka-band satellite earth terminals and VSATs. Lead design, prototyping, testing, feature corrections, and deployment for a global customer base. • Design and launch next-gen multicarrier product, equipped with multiple IBUCs for increased failover protection and continuity of service. • Team up with machinists, electrical engineers, software engineers, technicians, product managers, and other mechanical engineers to co-design hardware specifications, component layout, and BOM for head unit, controllers, parts, and fixtures. • Draft pre-production 3D renderings using SOLIDWORKS to showcase product features, functions, assembly, and installation guidelines – used in Marketing and POC pitches. • Perform extensive testing for thermal air flow and heat dissipation, as well as stress testing and tolerance stack-up analyses to validate form, fit, function, and cost. • Evaluate and adjust supply chain and manufacturing methods, and negotiate bulk discounts and competitive rates with new/existing vendors to boost performance and cut costs

Mechanical Designer (Contract)

• Aug 2019 - Mar 2022

Compliance Specialist (Two 1-Year Contract)

• 2018 - 2020

• Evaluated tens of thousands of product components for compliance according to RoHS, REACH, ISO 13485 and 9000, and FDA standards to safeguard global distribution. • Tripled output against contract, verifying compliance for 12 mechanical and electrical products instead of original assignment of 4, across a 1-year period. • Researched evolving health and safety regulations and reviewed BOMs for discrepancies, then adjusted drawings using Pro/E and SOLIDWORKS, and wrote ECOs to update component specifications. • Worked harmoniously with Compliance Engineer, Document Control Group, and designated suppliers to source materials documentation and develop compliance docs and reports.

Senior Mechanical Designer

• May 2016 - Oct 2017

• Recruited by Chief Engineer (and former supervisor) to design a less expensive, more energy efficient, and more compact mechanical system for SATCOM power amplifiers. • Disrupted the industry by architecting a top-assembly that is 25% lighter and smaller than the industry standard, and still capable of housing 300 components, each with hundreds of parts. • Innovated a fusion-style wave guide 50% shorter than baseline average to enable faster signal transfer, leading to 20% energy savings (below 10KW). • Sourced, evaluated, and onboarded 6 new vendors in the US and Canada, orchestrated bidding wars and negotiated bulk discounts on microwaves, travel tubes, 1-way and 2-way dividers, optical cables, coax cables, seal gaskets, and other mechanical parts integral to a smaller design. • Drafted detailed manufacturing design documentation and trained colleagues on product mechanical assemblies and sequence of events. • Oversaw first-article reviews and pre-production product evaluations for groundbreaking prototypes, just prior to management split and sale to SpacePath.

Mechanical Designer III

• 2011 - 2016

• Conceptualized and designed extremely reliable microwave subsystems and assemblies for high-power SATCOM power amplifiers used in remote units by DirecTV, CNN, MSNBC, ABC, and other major networks requiring powerful news feeds.• Translated highly complex engineering specifications into interrelated designs of components and sub-assemblies, using sound mechanical and electrical design principles.• Conducted materials checks and design reviews for 6 engineers specializing in electrical components, high-power supply, mechanical parts, PCBs, and thermo-analysis.• Generated detailed module assembly drawings and manufacturing documentation, laid out mechanical enclosures and mounts, and developed 3D CAD models of parts and assemblies.• Engaged vendors to evaluate parts, applications, and fixtures, including first-article inspections and prototype reviews. Worked with internal machine shop to make parts modifications.• Created custom fixtures and tools to facilitate subsystems assembly and testing. Worked in partnership with QA to ensure alignment with customer specifications.• Produced engineering instructions and slide decks to guide design, assembly, and testing.

Mechanical Designer II

• 2005 - 2011

• Led the creation of assembly instructions and drawings, interconnect diagrams, and 2D fabrication drawings, including geometry dimensioning and tolerancing.• Leveraged SOLIDWORKS to generate accurate renderings consistent with company design guidelines, industry standards, and customer requests.• Reviewed all designs for European RoHS and REACH product compliance as well as US ISO/FDA standards compliance, verifying materials and vendor certifications.• Entered data for Product Data Management (PDM) files and Document Management Systems (DMSs).

Mechanical Designer I

• 2000 - 2005

• Completed customer-requested upgrades and component replacements for previously implemented microwave products and systems, including specification design.• Created and updated SOLIDWORKS CAD models, drawings, and assembly guidelines.• Generated bill of materials (BOMs) for product assemblies.• Verified RoHS certifications across the supply chain through diligent review of supplier data sheets and continuous examination and approval of all components.• Partnered with Supply Chain Management and QA as well as contract manufacturers to vet and qualify suppliers; conducted quality audits and sought new vendors upon EOL of parts.

Mechanical Drafter

• 1997 - 2000

• Assisted engineers in drafting mechanical and electrical designs relating to microwave, electronics, RF, sheet metal, and machine parts for communication amplifiers and power supplies.• Implemented Engineer Change Orders (ECOs), updated drawings, and continually reviewed, trimmed back, and tidied document/specification archives.• Created and updated BOMs using construction-related drawings, and processed ECRs and ECOs.

Electronic Technician

• 1994 - 1997

• Provided mechanical assembly, kitting and transducer bonding, PC board inspections, testing, and debugging, using schematic diagram for troubleshooting. • Generated samples for assembly line, including final-test circuit boards and power supplies. • Provided mechanical assembly, kitting and transducer bonding, PC board inspections, testing, and debugging, using schematic diagram for troubleshooting. • Generated samples for assembly line, including final-test circuit boards and power supplies.