Composite Materials Expert Specializing in Aeronautical Design and Testing

Technical Consultant #2007


Expertise

  • Product development of advanced composite structures.
  • Aerospace structural design and weight optimization.
  • Polymer matrix composite Materials and Process (M&P) engineering.
  • Comprehensive test program development.
  • Micrograph analysis and ultrasonic NDI (A-scan, C-scan).
  • CapEx, certification, production and repair schedule assessments.

Experience

Undisclosed Company, Owner, Consultant, 2013 - Present

  • Solutions provider to the composites industry, specializing in generating fully-substantiated solutions to complex design and build challenges considering all aspects of product development, production, and operation.

Glenwood Springs Company, Glenwood Springs, CO, 2010 - 2013

  • Program Leader for the Airbus A320NEO advanced thermoplastic cargo liner module.
  • Defined requirements from Airbus specifications, led trade studies on fusion joining method of large assemblies.
  • Technical engineer of Sikorsky aircraft panels.
  • Validation testing of craft floor panels, administered deviation and change requests.
  • Provide substantiating analyses of manufacturing defects.
  • Developed resin-infusion repair methods for damaged panels.
  • Invented method to increase radius crushing strength of thermoplastic stringers by 80%.
  • Developed a patent-pending method for manufacturing a co-cured machined-features cargo-guide rail.
  • Led design-build-test efforts of stamp-formed TPC applications for customers including: Airbus, Boeing, Eurocopter, and Army Aviation Technology Directorate (AATD).
  • Designed matched-metal forming tooling and operated equipment, including presses, IR ovens, and automated tape layup machines.
  • Initiated the CCB (Configuration Change Board) to manage design changes and modify specifications.

Boeing Commercial Aircraft, Everett, WA, Aircraft Design Engineer (Configurator), 2007 - 2010

  • Led major composite structures design and manufacturing trade studies conducted: Reduced resin content material, outboard, high volume and lamination of wing skins.
  • Co-led dozens of successful trade studies with functional leaders, such as wing box structural fuel vent stringers, wing box EME optimization" (for lightning and electrostatics), and fuselage barrel ply eeductions
  • Led a cross-functional team to solve an urgent and high visibility manufacturing issues.

Wing Structures Analyst, 2006 - 2007

  • Composed and released official Boeing methodology memo for strength analysis of carbon fiber wing panel edges.
  • Performed wing panel stress analyses, including stringer run-outs (Nastran/Patran), LE/TE bearing-bypass joints, BVID, and 0.050" edge notch.

Product Development Composite Structures Engineer, 2005 - 2006

  • Planned and executed non-orthogonal laminates" test program, comparing structural properties of unique composite laminates. Reduced test data and recommended new laminate families for wing and stabilizer stringers.
  • Developed innovative new process to efficiently label composite test panels resulting in a U.S. patent.

Boeing Phantom Works Concept Exploration, Irvine, CA, 2007 - 2010

  • Filling several rolls: Airframe Leader, Composite Shop Manager and Composites Engineer.
  • Led team of 20 technicians and 3 engineers responsible for all tooling, fabrication, and testing of the composite airframe, including fuselage, main and tail rotor blades, cowlings, fairings, and landing gear.
  • Doubled efficiency of composite shop through improved materials, more efficient shop layout, and seamless coordination with engineering.
  • Selectively implemented Boeing lean manufacturing processes into Frontier Systems composite shop; outsourced composite parts and fuel cells to suppliers nationwide.
  • Created detailed estimate-at-cost (EAC) for engineering, tooling, and manufacture of all composite parts for eight aircraft; recruited, interviewed, and hired composite fabricators and structures engineers to meet increased rate demands of new DARPA contract.
  • Fabricated CFRP parts, including rotor-blade spars, cowlings, fairings, landing-gear legs, and bulkheads; performed field repairs of main structure longeron and skin-panel disbonds.

Honors & Publications

Credentials

  • Graduate Certificate: Aircraft Composite Structural Analysis and Design, University of Washington College of Engineering, Seattle, WA

Languages

  • Spanish-highly proficient

Academic and Professional Affiliations

  • Society for the Advancement of Materials and Process Engineering (SAMPE)
  • Composite Materials Handbook (CMH-17)
  • Handbook meeting contributor

Publications and Patents

  • Author and Co-Author of technical publications; (conferences, peer reviewed journals and magazines).
  • Several U.S. patents.

Education

  • B.S. Aeronautics and Astronautics, Massachusetts Institute of Technology, Cambridge, MA
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