Concept to production of all mechanical hardware for electrical meters. Optical probe accessory design. Cost reduction for Gen 6 Poly-phase (PP) meter relay vendor selection and integration for modularity. Gen 5 CT Meter, shielded disconnect option, Combo- and H1-PCBA integration with H1 full family of terminal covers. Oversaw engineering contractor and finalized design for M2M communications module for Gen 5 PP meter. Extensive water intrusion testing for IPX4 rating. Ongoing manufacturing support for hardware, cost reduction and EOL subassembly replacements.

DFM reviews and tooled sample FAI with vendors in Poland and China in person and remotely. Production and assembly support with in house staff and vendors. Verified pre-production samples for robustness, specifications and environmental testing; UV, IP, temperature.

Root cause analysis for Legacy product issues (electrical contact, unintended latching). Surfacing and design of Long and Short meter terminal covers for Single-Phase (SP) and PP variants. Electro-mechanical integration of latching relays for Gen 4 family of meters as well as other proposed bids. Soldering station fixture for manufacturing (concept, mockup, prototype test). Hardware selection and acceptance testing (screws, nuts, corrosion root cause, accelerated life tests). Directed supporting drafting and designer staff. Migrated 3D CAD data into managed database to improve version and revision tracking, reducing erroneous tooling errors.

Lead Mechanical Design engineer from concept to production of EdgePoint-R8/-S16/-R6 outdoor routers/switches and accessories for mass production (10,000’s/month). Extensive work in plastic injection molding, aluminum die casting and sheetmetal design for robust structures with emphasis on aesthetics and user experience. Designed and tested units for cooling with heat pipes and heatsinks as required by thermal load in conjunction with enclosure designs. Designed mounting accessories for combined wall and pole applications with innovative securing solutions, enhancing visual appeal through minimalist and hidden features.

Patent 20210105543 for EdgePoint Family of products: See Link

Basis of Estimate (BOE) reports for customer design proposal. Technical writing reviewer.

Mechanical design and onsite Manufacturing support Lead: DX rated Armored Split hatch contract ($24 million) with patent pending. Designed usability enhancements and lead prototypes build at manufacturing vendor site. Analyzed GD&T for mechanism to ensure proper function, minimize cost, and ease manufacturability. Designed improvements to environmental sealing to minimize dust and water intrusion and developed testing plan used for manufacturing to ensure compliance. Worked closely with parts suppliers to customize parts to optimize hatch usability.

Subsystem layout design and integration lead: Vehicle layout for Mine Blast attenuation seats and designed integration brackets for several vehicle platforms including legacy vehicles and competition sensitive vehicle platforms. Worked with modeling and simulation groups to ensure integration robustness through vehicle automotive and mine event load cases. Integrated various armor solutions to vehicle platforms per government requirements; including bar armor and spall liners. Authored design guide for bar armor.

Testing Support: Fixture design for full up vehicle mine blast testing. Wrote test plans for ballistic coupons to verify survivability at various threat levels. Wrote test plan for survivability demonstrator vehicle hull with mine test. Lead onsite assembly of fixtures and ballasting.

Project Management: Directed efforts of drafting and designer staff to assist in drawing creation for programs as required to meet project schedules for all projects. Lead requirements and design reviews with customers.

Patent 20140230640 for Armored Split Hatch: See https://patents.justia.com/patent/20140230640