Darby Prototype provides consulting services to start-ups, established firms, and individual visionaries. We are a one-stop solutions shop for early stage and headed-to-market products. Customers include electric vehicle and medical device manufacturers, industrial design firms, and computer hardware developers.

• CAD modeling and analysis • Design for Manufacturing • Fabrication using rapid prototyping processes (3-D printing, laser-cutting, CNC machining) • Short run production • Supplier sourcing and support of manufacturing kick-off • Quality documentation and specifications

• Directed day-to-day design/build/test activities for teams of engineers and technicians assembling and testing Combined Heat and Power, waste heat recovery, and emissions reduction systems

• Managed project budgets, schedules, and milestone deliverables for multiple simultaneous energy efficiency projects funded by the US Departments of Energy and Defense, and the California Energy Commission

• Designed and oversaw fabrication of custom R&D combustion and vacuum systems. Common tasks included Solidworks CAD design, drawing creation/checking, fabrication review and issue resolution, and test data analysis.

• Learned advanced writing and editing skills applicable to a wide variety of genres and projects

• Taught and tutored writing, physics, and statistics for undergraduate and graduate students

• Designed and taught college courses in modern literature and analytical writing

• Evolved design and manufacturing status of R&D hydrogen fuel cell designs into market-ready products

• Designed high-temperature/pressure liquid fuel reformers for automotive & industrial hybrid power, under support from US Department of Energy and commercial clients

• Oversaw the casting, machining, welding, and assembly of prototype reformers and fuel cell components fabricated from aluminum, stainless steel, and high-nickel alloys. Many components designed for quick-turn manufacturing methods (e.g water/laser jet), CNC machining, and hand assembly/welding.

• Responsible engineer for design/quality of Premium V-6 pistons, connecting rods, and intake manifolds

• Analyzed fatigue life and projected durability of high-stress rotating and reciprocating machinery; designed durability tests (bench-top and running dyno) to verify same

• Managed multiple simultaneous projects involving over twenty Tier I suppliers and prototype shops

• Chrysler Institute of Engineering (1998-2000): Full time, two year, rotational training program; completed six rotations in product design, high-volume manufacturing, and fatigue/shock/vibration testing

• Vehicle Engineering Intern (1996-1998): Three summer internships in engine dynamometer testing, component design, and sheet metal stamping/tolerancing.