Engineering- Design and Manufacturing

  • Implementation Of A Laser Cutting Punch Press For Sheet Metal Fab – Created and implemented capital equipment projects for tooling, maintenance and machine tools, including the installation and training for a $500,000 CNC laser cutting (Trump 180LW). Resulting in savings of $270,000 per year in fabrication of sheet metal parts for air circuit breakers.
  • Design Of Aluminum Casting For Business Machine – Designed on the CADAM (Computer Aided Design & Manufacturing) system a complex aluminum casting which formed the backbone of a document transportation system (IBM 4723 Document Processor). This was from the conceptual stage to N.C. models and included various pulleys, mechanisms and assemblies. Specified the methods of manufactured of the N.C. models in the model shop. A by-product of this work was to demonstrate to the existing design staff the utilization of CAD. Operations Improvement and Industrial Engineering
  • Development And Implementation Of Equipment And Tooling For Composite Aircraft Manufacturer – Developed and implemented equipment specifications (ovens, autoclaves, freezers, waterjet cutting machine) to manufacture the all composite six-seater aircraft Lear Fan 2100 (graphite-epoxy). Determined special tooling required for trimming and drilling cured composite material . Designed fixtures for storage of pre-preg rolls in fridges. Established plant layout in this, the startup phase of the plant. Designed a baffle for the ovens and fixtures for fuselage, wings and nose cone for support in autoclaves.
  • Design And Development Of Machine Shop Tooling For High Precision Aircraft Components – Designed jigs, fixtures and cutting tools for manufacture of a variety of aircraft components that required high precision machining. Tools included milling cutters, forming tools, reamers, carbide tipped tools , drill jigs, checking fixtures and milling fixtures. Materials to cut included stainless steels, nimonic alloys, mild steels, and other aircraft related materials.
  • Design And Development Of A Layup Mould For Helicopter Rotor Blade – Conceptually designed a metal layup mold on CADAM for manufacture of a composite main rotor blade (Kevlar-Epoxy) of the U.S. Armies advanced attack helicopter (YAH-64). Carried out heat transfer by convection analysis including the energy required to cure the blade. Developed manufacturing processes to manufacture the blade through the various stages, including winding of spar mandrels, layup of pre-preg Kevlar roles and curing cycles.
  • Design Of A Composite Layup Mould For Aircraft Leading Edge – Designed high temperature (Kevlar-Epoxy) layup mold to manufacture the outer leading edge of the Dash-8 aircraft, and developed standard manufacturing processes for composite material parts production. Specified the equipment required for fabrication of composite parts (ovens, autoclaves). Processes included the various stages from the Master model through to layup of laminations of Kevlar cloth. Techniques included vacuum bagging and determining curing cycles. Liaised with Engineering R & D, Composites Lab, Model Shop, Plastics Shop, Manufacturing and Industrial Engineering. Female mold included overcoming problems such as tolerances, obtaining smooth aerodynamic surface and expansion ratios.
  • Development Of Process Plans For Aircraft Component Parts – Carried out process planning of aircraft components manufactured in the machine shop from raw material to treatments and finishing operations. Created operations sheets and specified tooling, and N.C. programming required. Contracts included Boeing 727, Fokker F28, SD3-30, SC7, DC10.
  • Development And Implementation Of Equipment And Tooling For Composite Aircraft Manufacturer – Developed and implemented equipment specifications (ovens, autoclaves, freezers, waterjet cutting machine) to manufacture the all composite six-seater aircraft Lear Fan 2100 (graphite-epoxy). Determined special tooling required for trimming and drilling cured composite material . Designed fixtures for storage of pre-preg rolls in fridges. Established plant layout in this, the startup phase of the plant. Designed a baffle for the ovens and fixtures for fuselage, wings and nose cone for support in autoclaves.