Senior Mechanical Engineer

• Sep 2021 - Present

Senior Mechanical Engineer, Project Engineer

• Feb 2016 - Sep 2021

• Responsible for the technical oversight of the mechanical engineering group. • Project engineer for new product development, which includes running interdepartmental project meetings, and maintaining project schedule. • Administrator for CAD vaulting system and overall document repository for entire engineering group • Produced technical documentation including system specifications, design specifications, test procedures, test reports, design review presentations, etc. • Developed conceptual models, as well as detailed component/assembly designs and drawings using SolidWorks. • Develop mathematical models of mobile robot dynamics that fed design specifications. • Designed complex electro-mechanical systems utilizing brushed/brushless DC motors, linear actuators, custom gear trains, dynamic cable tracks, navigation and obstacle detection sensors (LIDAR, ultrasonic, time of flight, 3D cameras), safety rated electronics, computers, batteries, etc. • Design components for manufacturing methods such as CNC machining, sheet metal, thermoforming, injection molding, 3D printing, casting, aluminum extrusion, etc. • Performed FEA on critical components and assemblies using ANSYS for validation of safe design, as well as providing expected system life. Analysis involves statically and dynamically loaded structures analyzed for stress, deflection, natural frequencies, fatigue life, as well as thermal. • Performed investigative research into new technologies and components useful for the success of projects. Show less

Mechanical Engineer II

• Feb 2011 - Feb 2016

• Designed robotic vehicles, manipulators, and end effectors for military contracts specializing in explosive ordinance disposal, combat troop support, and reconnaissance. • Conducted detailed stress, deflection, and thermal FEA analysis using ANSYS and COSMOS to meet strict design requirements. • Designed robotic mechanisms utilizing brushed/brushless DC and AC motors, encoders, custom gear reduction units. • Designed and analyzed electromechanical systems for specific heat transfer qualities in order to maintain allowable operating temperatures in harsh environments. • Analyzed component and system assemblies for proper tolerance stackups to achieve desired performance. • Created detailed manufacturing drawings for high precision components using geometric dimensioning and tolerancing (GD&T). • Wrote specification documents that drove electro-mechanical design and component selection. • Performed Mil Std. testing at certified testing labs on various components to meet environmental and vibrational requirements. • Performed failure modes and effects analysis (FMEA) and summary reports for product development. • Operated milling machine, lathe, various shop equipment to quickly prototype ideas and concepts. • Performed inspection of components using machinist equipment such as dial calipers, dial indicators, micrometers, and bore gages. • Performed continuous research into currently available mechanical and electrical technologies that may be implemented into robotic products and systems. Show less

Mechanical Engineer

• Jun 2009 - Feb 2011

• Designed and implemented positive displacement blower systems for water treatment plants, landfill gas recovery systems, and pneumatic conveying packages. • Designed aluminum sheet metal equipment enclosures with specific acoustic and thermal properties. • Designed high-speed power transmission shafts for blower system jackshaft applications. • Performed heat exchanger analysis for development of a new heat exchanger product line. • Met with current and future customers to discuss technical application information, as well as troubleshoot current fielded systems. • Designed and produced manufacturing prints for structural steel blower system base weldments. • Conducted system testing for allowable vibration, noise, thermal properties, flow rates, and pressures. Show less

Mechanical Design Engineer

• Aug 2004 - Aug 2008

• Designed robotic vehicle chassis and components for small production runs of autonomous vehicles. • Arranged daily purchase orders for project materials and components. • Met with customers to discuss details such as design changes, deadlines, and future contracts. • Contracted through Carnegie Mellon to work with respectable companies in the Pittsburgh area on various design projects ranging from Defense Department vehicles, to rugged underwater fiber optic couplings. • Example projects I designed components and assemblies for: Autonomous underground pipe mapping robot, submersible fiber optic coupling, underground mining cart, robotic wounded soldier extraction system, amphibious land mine detection vehicle, flywheel inertia driven car. Show less

Machinist

• May 2005 - Dec 2005

• Operated CNC and manual milling machines, lathe, sheet metal equipment, and welder. • Gained valuable knowledge of machining operations and fabrication processes. • Met with customers to finalize orders and deliver parts. • Read and understood complex part and assembly drawings for programming CNC machines. • Operated CNC and manual milling machines, lathe, sheet metal equipment, and welder. • Gained valuable knowledge of machining operations and fabrication processes. • Met with customers to finalize orders and deliver parts. • Read and understood complex part and assembly drawings for programming CNC machines.