Chelmsford, Massachusetts, United States
I graduated from the University of Massachusetts Lowell in the spring of 2018 with a Bachelor of Science in Mechanical Engineering degree with a focus on aerodynamics and project management. After graduating I found myself at a unique company with the vision to create the world’s first NHTSA FMVSS compliant, FAA-certified, flying car. I began at Terrafugia as a composite technician where I was creating the composite parts that would form most of the Transition®. I quickly learned the intricacies and difficulty of laying up composite structures by hand; about pre-preg, infusion, and wet-layup. Soon after I moved to mechanical technician where my role had me bonding the very parts I had created to form crash test vehicles, drive only vehicles, and E-LSA certified vehicles. In addition to composites bonding, there was mechanical fabrication systems such as crash beams, cooling and brake lines, suspension, flight controls, and more. Due to my experience in machining I also created several custom metallic pieces that would form critical structures such as the crash rail and flight controls. Eventually I moved to the engineering side of Terrafugia within the chassis group. Here I found myself responsible for the integration and documentation of the front and rear suspension. I quickly found myself loaned out to other over-loaded groups where I acted as both the mechanical designer and the engineer for the parachute deployment handle, as well as the attachment points for the occupant restraint. Upon the departure of the engineering manager responsible for those systems, I was placed in charge of the remaining design, integration, and documentation of the parachute deployment handle and the entire occupant restraint system, in addition to my responsibilities within the chassis group. Soon after it became evident that significant redesign of critical components within the suspension was required, which I successfully performed and validated with the help of external FEM consultation, and thus began a pattern of required re-designs and re-analyzing parts due to changing loads. By the end of S-LSA certification most of the suspension systems had been redesigned or re-evaluated to ensure they still could meet the ever-changing strength requirements. During the certification process I successfully managed testing of the systems, redesigning systems as required, manufacturing concerns, as well authoring structural substantiation documentation and the associated analysis documentation.
• Performed detailed failure modes and effects analysis (FMEA) on complex mechanical sub-systems in the hydrogen power system, identifying potential failure points and recommending design improvements. • Contributed to a functional hazard assessment (FHA) and design description document with a multidisciplinary team for a hydrogen power system. • Conducted thorough reviews of FAA regulations and published aerospace documents on hydrogen certification and safety to generate a new set of requirements for the liquid hydrogen fuel cell design. • Developed a custom tool to automate the analysis of bills of materials (BOM) with a focus on reducing weight and cost of a powered lift aircraft. • Established a theoretical benchmark for the minimum weight and volume of the aircraft's power generation system and analyzed a series of conceptual redesigns to improve the system.
• Lead for deployment of semi-automated model based producibility software DFMPro • Primary instructor for all Raytheon on producibility software DFMPro • Lead designer for battery filter bracketry on NASAMs product line upgrade • Multiple awards for collaboration given within first year of employment • Trained in model-based definition method of authoring CAD models • 40-hour instructor-led GD&T training based on ASME Y14.5-2009
• Supported R&D, prototyping, manufacturing, and documentation that lead to an S-LSA certified aircraft. • Designed, tested, and integrated the front suspension, rear suspension, occupant restraint, and parachute deployment for Light Sport Aircraft and Low Speed Vehicle. • Authored chassis system documentation for design, test, and analysis documentation; internal and external audits; and other activities as needed. • Championed a vehicle drop test per 14 CFR Part 23, as well as static testing of various chassis components. • Coordinated analysis and testing with external consultants, as well as DFM with external suppliers to reduce part complexity and cost.
• Mechanical assembly and composites prototyping of combination aviation-automotive vehicle • Interpret GD&T drawings to assemble mechanical components and assemblies such as suspension, power-train, and cooling • Provide DFM feedback to senior manufacturing engineers to increase manufacturability of prototype to production • Propose design changes to mechanical design engineers to conform to industry standards and increase safety of vehicle • Devise and execute on the fly problem solving of designs to meet critical path deadlines • Program and Operate Haas VF1 3-axis CNC Mill to create in house rapid prototype metallic parts
I served in a team leader position in which I was responsible for three junior soldiers. I held the rank of Specialist (E-4). My job was to train, lead, and perform military police combat operations as needed by the U.S. Army reserve. Achievements: 3 Certificates of Achievements for hard work during annual training Army Achievement Medal for dedication to teaching weapons system to junior and senior enlisted