• Owned the mechanical design for the Gen 2 and Gen3 platform involving light-pipes, interconnected PCBs, current and voltage sense clips, thermal management strategies, EMI management and complex harness designs within tight volumetric constraints.

• Responsible for mechanical and thermal packaging for GEN3 modular products by delivering mechanical architecture with an optimized assembly integrating busbars and PCB housing that met certification (UL, NEC, FCC), automation, and reliability standards.

• Designed complex electromechanical assemblies integrating sheet metal, heatsinks, plastics, high voltage connectors and busbars with intricate tolerance stacks; partnered closely with manufacturing vendors and quality teams to optimize processes and maximize production yields.

• Experienced in DFM, DFA, statistical tolerance analysis and geometric tolerancing for high volume manufacturing in China and Mexico. Conducted several RCAs using 8D principles, DOEs to resolve manufacturing issues and worked with vendors to bring processes under control.

• Managed programs, mentored interns, functioned as a technical leader, and collaborated with cross-functional teams, including Reliability, Certification, Quality, Thermal, Electrical Hardware Engineering and Operations to deliver projects under tight deadlines.

• Successfully launched two generations of flagship products at SPAN from concept to mass production, interacting with interdisci-plinary teams and managing multiple deadlines

• Responsible for mechanical design of plastic, sheet metal and copper/ aluminum components, connectors, insulators, harnesses and fasteners used in consumer electronic products adhering to UL, NEC and IP requirements

• Developed innovative solutions to meet functional design requirements through rapid prototyping, testing and validation

• Defined component and system specifications, created detailed designs in CAD, prototype, test, and document to release for manufacturing

• Extensively performed FAI, GD&T and tolerance analysis and worked through DFM challenges with external vendors

• Responsible for DFA, assembly instructions, determining Torque values, making assembly drawings and fixture development with CM