St Clair Shores, Michigan, United States
I've spent 40+ years building things that matter — from stealth bombers to rocket launches, jet engine silence to 100,000+ automotive parts shipped worldwide, six consumer products on the market, and now the cutting edge of AI. My career started on the factory floor in my early 20s — working the F-20 Tigershark fighter program, then the YF-23 advanced tactical fighter. I earned my Master's in Aerospace Manufacturing Engineering at UCLA, focused on aerospace manufacturing and tooling, then spent five years on the B-2 stealth bomber program. After the Space Shuttle disaster, I was brought onto the Atlas rocket program — stood up the first cut stainless steel manufacturing area and engineered the rocket to avoid a $1 million per day late penalty for a Japanese satellite launch. On time. On budget. At ROHR (now Collins Aerospace), I engineered the noise reduction technology that allowed commercial aircraft to fly after 10:00 PM — changing airport curfew rules worldwide and reshaping the economics of late-night air travel. I returned to Michigan to build a design and engineering team at Eifel Mold & Engineering, pioneering the industry's first high-end airbag covers and the first complete Ford Windstar interior program. In 2001, I founded Halpin Design (now Halpin Solutions), releasing 100,000+ automotive parts across nearly every major manufacturer — from Detroit to Shanghai, Stuttgart to Tokyo. Beyond engineering, I'm a prolific inventor and product creator: • PowerSk8r — #1 Amazon Best Seller, five-star hockey training product (US, Canada, expanding to Europe) • Goonis Pick — 3D asymmetrical guitar pick endorsed by Grammy Award-winning musicians • Microsoft Surface Tablet — contributed to design and engineering • Proud Mary Prosthetics — patented silicone breast prosthesis for cancer patients • Silent Call — alert systems protecting blind, deaf, and handicapped people in hotels I've personally trained 20+ young professionals to become automotive design digital modelers — many now lead design teams globally. I mentored inventors like Larry Kelly, whose Gyro swing trainer placed 6th of 500 on the Golf Channel's "Fore Inventor's Only" and was acquired by Skilz Corp. Today, I lead Halpin Solutions-AI — applying cross-industry pattern recognition to AI, space systems, America's Cup sailing technology, data centers, defense, and beyond. The vision never stops.
I've spent 40+ years building things that matter — from stealth bombers to rocket launches, jet engine silence to 100,000+ automotive parts shipped worldwide, six consumer products on the market, and now the cutting edge of AI. My career started on the factory floor in my early 20s — working the F-20 Tigershark fighter program, then the YF-23 advanced tactical fighter. I earned my Master's in Engineering at UCLA, focused on aerospace manufacturing and tooling, then spent five years on the B-2 stealth bomber program. After the Space Shuttle disaster, I was brought onto the Atlas rocket program — stood up the first cut stainless steel manufacturing area and engineered the rocket to avoid a $1 million per day late penalty for a Japanese satellite launch. On time. On budget. At ROHR (now Collins Aerospace), I engineered the noise reduction technology that allowed commercial aircraft to fly after 10:00 PM — changing airport curfew rules worldwide 2001, I founded Halpin Design (now Halpin Solutions), releasing 100,000+ automotive parts across nearly every major manufacturer — from Detroit to Shanghai, Stuttgart to Tokyo. Beyond engineering, I'm a prolific inventor and product creator: • PowerSk8r — #1 Amazon Best Seller, five-star hockey training product (US, Canada, expanding to Europe) • Goonis Pick — 3D asymmetrical guitar pick endorsed by Grammy Award-winning musicians • Microsoft Surface Tablet — contributed to design and engineering • Proud Mary Prosthetics — patented silicone breast prosthesis for cancer patients • Silent Call — alert systems protecting blind, deaf, and handicapped people in hotels I mentored inventors like Larry Kelly, whose Gyro swing trainer placed 6th of 500 on the Golf Channel's "Fore Inventor's Only" and was acquired by Skilz Corp. Today, I lead Halpin Solutions-AI — applying cross-industry pattern recognition to AI, space systems, America's Cup sailing technology, data centers, defense, and beyond. The vision never stops.
Server Rack Redesign and On-Site Manufacturing Optimization Data Center Infrastructure Project at DDC Led the comprehensive redesign and on-site remanufacturing of server storage racks tailored for high-density data center environments. Collaborating closely with data center operators and rack integration teams, I delivered a modern, highly efficient assembly that significantly reduced material usage, assembly complexity, and overall costs while enhancing performance and serviceability. Applied advanced Design for Manufacturability (DFM) principles to eliminate over 50% of sheet metal components, streamlining production, reducing weight, and improving structural integrity without compromising load-bearing capacity or seismic compliance. Adopted an innovative "inside-out" design methodology, beginning with critical rack attachments (rails, PDUs, cable management) and progressing outward to doors, side panels, and cooling integration—resulting in a modular, future-proof architecture optimized for rapid deployment and easy upgrades in live data center settings. Achieved more than 50% reduction in cabinet production costs through intelligent part consolidation, material optimization, and simplified assembly processes, delivering substantial CAPEX savings for data center buyers and OEM partners. Engineered integrated cooling coils and optimized airflow dynamics to enhance thermal efficiency, supporting higher power densities and improved PUE in air-cooled and hybrid cooling deployments. This redesigned rack system offers data center owners and server rack design companies a cost-effective, scalable solution that accelerates time-to-deployment, lowers total cost of ownership, and supports evolving AI/high-performance computing requirements.
I am here to announce my teams services are 100% at your call. We can help with any back log of product development. From Sketch to show car we can help. From your dream product to Shark Tank we will build it. From your vision to tooling we can lead and mentor it. I have 10 digital modelers and engineers available to serve your studio or help you invent your dream product to sell on Amazon.
http://www.trucktrend.com/news/1703-workhorse-w-15-electric-pickup-truck-receives-letters-of-intent/?sm_id=organic_fb_social_TTN_170303_sf59999758#sf59999758 This is our 6-month cartoon concept to design to build a show car project with Dave Ross and my team at Halpin Solutions. Come see it unveiled in Long Beach May 1st. Not a new job but a great project completed at my company. Thanks
We have turned over the music industry with a guitar pick design with the finger and thumb as the main feature in holding the pick.
We launched the new aerodynamic Powersk8r product launch in 2006. It has since been 100% successful. Every client has seen great gains in speed when wearing for 90 days. A 5-30% increase in speed is always the case. Developed and tested for years prior to product development and manufacturing. With 21 state championships between 2 coaches. The skate weight optimizes the practice ice time while providing maximum resistance with every stride. Now internationally used throughout North America including Canada. Individuals and teams have all seen great gains in speed without the extra ice time, and or cost of off-ice training. Teams and organizations sell them as fundraisers. $10 of every pair can go toward power skating training or tournament and travel cost or even team parties. Camps can make an extra $2000 for every 100 students and send the kids home with a product that really works. Contact us to discuss working together to Make America Faster Skaters.
Get ready Southern California! I am opening an office to support the studio workload and overflow styling and A-surface work. I have a data farm in Michigan with designers that grow data. Concept design and development of entire cars and interiors. My office will also be the headquarters for our fall risk alert product for hospitals and my latest invention for www.notAhole.com Golf putting training. Currently, supply concept through production skill through staffing to all automotive companies in need. We support studio engineering, program management, clay modeling, A-surface design, V5 Alias, UGNX, ICEM, Color and trim, Machine fabricators, Interior ad Exterior stylist. 3D scanning with Atos white light scanner, B-side development. Mechanical engineering, Interior and exterior styling and A-surface, Staffing, and inspection.