James O'Connell

• Lead design engineer on revolutionary new ski boot design, featuring BOA® Alpine closure system • Designed, engineered, and tested ski boots, components, and assemblies using Creo (Pro/E), Rhino 3D, Solidworks • Managed ski boot laboratory test program, thoroughly tested products for fit, function, quality, durability • Led product failure investigations, collected, organized, and analyzed warranty and test report data • Performed hands-on engineering to design and manufacture instrumentation, test fixtures, and tools • Traveled to and collaborated with overseas factories on initiatives to improve manufacturing quality and efficiency • Developed and maintained accurate specifications, tool lists, and development lists • Performed product training presentations for customer support, sales teams, and retail shop personnel • Traveled to attend industry trade shows, sales clinics, and on-snow product demonstrations • Communicated, interfaced with vendors and suppliers to source components, hardware, materials, and tooling • Constructed, render photorealistic digital assets using Rhino 3D and KeyShot for marketing purposes • Designed and applied organic parametric geometry using Grasshopper

• Designed, engineered, and fabricated innovative tilt-adjustable steering system for Formula 1 style race car • Performed Finite Element Analysis (FEA) on 3D Solidworks models and assemblies, validated engineering decisions • Organized complex full-vehicle Solidworks assembly, containing more than 2,000 3D parts and components • Led team of 20 mechanical engineering students to design, fabricate, assemble, and test a Formula 1 style race car • Implemented cloud-based project management software to manage timeline and workflow of 5 design sub-teams • Achieved 9-month engineering project goals utilizing critical path analysis, work arounds for challenging problems • Instructed 20 engineering students in ASME Y14.5 - 2009 (GD&T), developed team-wide drawing review system • Utilized mill, lathe, water jet, TIG welder, and other equipment to fabricate mechanical components for race car

• Hired by TEES to consult student competition teams on engineering design process, problem solving methods • Advised undergraduate and graduate students on design for manufacturing (DFM), correct 3D modeling techniques • Designed complex mechanical assemblies for special projects including solar panel array, composite materials rack • Taught machine shop safety, proper mill & lathe operations to students in Mechanical Engineering department • Reverse engineered and fabricated bespoke components to repair machine tools, mills, and lathes

• Designed 3D parametric models in PTC Creo adhering to plastic design guidelines for injection molding • Conceptualized 5+ machining fixtures in Inventor and Mastercam for production of 20+ engine components • Spearheaded $30K grant proposal to purchase CO2 laser cutter and additional manufacturing equipment • Developed curriculum, instructional materials, teaching aids for department’s CAD/CAM program • Programmed and operated HAAS CNC mill and lathe, producing prototypes and small-batch parts

• Aided in merchandise buying, expanded assortment of bicycles, soft goods, parts and accessories • Developed marketing sales and visual merchandising plans, increasing company profits by 15% • Supervised bicycle service department and trained employees in complex repair techniques

• Managed bicycle sales and service department of sporting good retail store producing $2.5 million annual sales • Developed turnkey multi-discipline bicycle fit program and deployed company-wide across 20+ stores • Attended Interbike twice, industry conferences, sales trainings to follow new product developments, technologies • Trained over 15 employees in sales processes, ski and bicycle repair, and coordinated new-hire orientations • Supervised ski and snowboard sales, service, and bootfitting over a period of 3 winter seasons • Designed visual merchandising displays, overhauled backroom organization, optimized inventory storage systems

• Serviced fleet of 100+ performance rental bicycles, performed basic repairs, tune-ups, and full overhauls • Performed suspension and hydraulic disc brake services including upgrades and rebuilds. • Consulted with customers regarding bicycle performance issues and made repair proposals

• Overhauled rental department organization, visual merchandising displays, and rental equipment storage • Assembled bicycles, tuned and adjusted components, performed pre-sale bike safety inspections • Engaged with customers to provide service, technical product information, and match products to customer needs