As the mechanical engineering representative on a multidisciplinary team, developed electronics modules and ground support equipment used in Insitu UAS's. Design challenges included harsh service environments, portability requirements, thermal management issues and a highly compressed schedule. Using SolidWorks and working with CAD designers, created drawing packages used in the build of electronics modules and test tooling, including detail level sheet metal and machined parts, cable and harness definition and routing, top level assembly, subassemblies, and system level drawings and BOM's. Acted as subject matter expert (SME) for the Mark 1 SkyHook recovery system.

Supervised the work of four specialized engineers on site, and three machinists off-site. Coordinated sustaining work as well as R&D projects through both departments. Worked closely with production managers and optical technicians to design and fabricate the process tooling and systems required in the manufacture of custom optical components. Coordinated the implementation of the PDMWorks Enterprise system. Administered SolidWorks and PDMWorks Enterprise. Designed and implemented procedures in both departments to bring them into ISO regulatory compliance.

Acted as lead engineer in charge of new radome designs and existing radome improvement projects all radomes, ranging in size from 12 inches to 16 feet in diameter. Redesigned composite tooling to meet quality standards. Designed the next generation of high performance “RF tuned” sandwich core composite radomes and developed an innovative process to produce them quickly and economically. Successfully tested new radomes to Mil-S-901D shock survivability and DNV Offshore Environmental Service Specifications. Led teams of designers, technicians, and machinists on various projects. Acted as mentor to less experienced engineers.

Developed a technique and designed fixtures for in process inspection and thermal and vibration testing of complex electro-optical and PCB assemblies used in the THAAD missile guidance and control system. Utilizing this technique before hard wiring PCB’s into the final assembly enabled production to reduce cycle time from over five days to less than one day. Fabricated prototypes and designed all related tooling for use in this process. Published process documentation and tool usage instructions.