Resume

Skills

Experience

Manufacturing Engineer – MightyFly               
Feb 2022 – Present

• Led composite tooling design and manufacture for two aircraft programmes: MF100-10 and MF100-20
  • I designed, manufactured, processed, and maintained assembly and lamination tooling for two aircraft programmes.
  • Lamination tooling was a mix of epoxy tooling board (RenShape BM5060T) and metallic (AL MIC-6) depending on application.
  • Assembly tooling was metallic (AL 6061) or SLS/MJF Nylon depending on application.
• Full DFM lifecycle design and implementation of eVTOL and wing assemblies for long-range cargo drone
  • I led the design and manufacture of -10’s Vertical Lift System and -20’s Forward Wing and Landing Gear system
  • Design started from clean sheet requirements and hand calculations to detailed CAD and tooling design, through until part manufacture, system testing, flight testing, and sustainment.
  • All composite components on the aircraft were made in house.
• Led acquisition and installation of $100k CNC machining suite and accompanying machine shop
  • As employee #7 at MightyFly and #3 on the Mechanical Team, no machine shop existed at the company prior to my arrival.
  • I led the effort to investigate and acquire a bespoke CNC 3-Axis router for use with machining our composite tooling and auxiliary components
  • Responsible for soliciting bids, leading inter- and intra-company tagups to evaluate candidate performance, and the procurement and installation of the CNC in our HQ.
• Designed, built, and managed bespoke high-volume curing oven for large composite aerostructures
  • In the absence of suitable high-temperature curing ovens that fit our size, temperature, and budget parameters, I designed and constructed a fully custom curing oven for use with our out-of-autoclave prepreg carbon fibre parts.

Manufacturing Mechanical Engineer – Opener    
Jun 2020 – Jan 2022

• Increased fuselage skin manufacturing throughput by 800% through the use of large-component 5-Axis Machining
  • Fuselage skins were machined in large, gantry-style 5-Axis machine
  • I optimized both the program side (through CATIA CAM) as well as the tooling side (through the use of new tooling types like spring-loaded depth-controlled endmills) to increase throughput on the fuselage machining line.
• Distilled disjointed CAD into single-source-of-truth models through the use of CATIA publications and auto-update features
  • Up to this point, CAD at Opener had no formal interdependencies and significant time was lost to repairing links and features, overwriting design elements, having disjointed sources of truth, etc.
  • I implemented a teaching program on the use of CATIA publications, which alleviated a large portion of dependency issues.
• Led several interdisciplinary projects creating electrical and mechanical assembly and verification fixtures to increase repeatability and reduce operator fatigue
  • Notable fixtures include a ceramic induction heating fixture to solder non-standard SMT components to a PCA, a machining fixture to modify mounting tabs on a radar unit, and conformal coating masks to allow for better controlled application of conformal coating to in-house PCAs.

Flight Test Engineer – Opener            
Jun 2020 – Present

• Validated aircraft-level systems to FAA Part 103 through autonomous test flights
• Organized personnel, equipment, logistics and goals to execute flight testing at 2 remote sites up to 5 times a week with a team of 6
• Coordinated and performed in-field repairs under high time pressure and with minimal impact to test vehicles or delays to test schedule

Capstone Project – University of Waterloo                     
Sep 2019 – Mar 2020

• Designed a fireproof and waterproof Kevlar composite wearable device that leveraged machine learning to detect hazardous fire conditions and alert the firefighter using visual signals.
• Developed an innovative Aerogel/Kevlar composite layer to thermally isolate electrical components, safeguarding against heat damage in high-temperature environments and open flame.
• Created compact, lightweight housings to efficiently package cameras, sensors, and a mask HUD while still remaining ergonomic and easy to wear and carry.
• Responsible for housing design, cable chafe guard design, and integration of PCAs and sensors.

Mechanical Team Lead – UW Autonomous Sailboat             
Sep 2016 – Sep 2019

• Led design and OML shape optimization of dual rudder system, doubling control authority during high roll angle tacking maneuvers while simultaneously reducing hydrodynamic drag by 50%.
• Designed and CNC-routed lamination tooling for all composite components of the boat (hull, keel, deck, rudders) with some parts reaching 2 meters in length.
• Implemented waterproof hatch and bulkhead system increased sub-deck access while protecting vital electronics
• Co-led a cross-functional team of 15 mechanical, electrical, and systems design students through fast-paced 6-month build cycles, coordinating tasks, maintaining timelines, and ensuring successful on-time delivery of key project milestones.

Search and Rescue Rover Project – University of Waterloo           
Jan 2016 – Apr 2019

• Designed and fabricated a laser-cut Delrin chassis, high-flow long-throw air nozzle, and sensor integration mounts for a compact all-terrain search and rescue autonomous mobile robot. 
• Enabled the robot to traverse adverse terrain (water, pits, gravel, sand, rocks), locate and extinguish fires, as well as seek and identify non-metallic targets using integrated sensors. 
• Led the sizing, design, and build of the chassis and drivetrain, conducted sensor integration, and developed ingress prevention to ensure durability and reliability of the robot system in challenging environments.

Mechanical Design Engineer – Avidbots Corp.                           
May 2019 – Aug 2019

• ​​Developed an automated mean-time-to-failure test rig to analyze lifecycle performance of autonomous cleaning robot components – such as tank lids and battery doors – up to 1 million cycles. 
• Reduced manufacturing costs by 80% for water distribution systems in a family of variously sized robotic cleaning heads by optimizing materials and streamlining component routing.

Exoskeleton Mechanical Designer – Tréx­ō Robotics           
Sep 2018 – Dec 2018

• Redesigned human-facing ankle joint on medical rehabilitation robot with innovative quick-detach system, reducing device preparation time by 75% and improving joint strength by 300%.
• Increased packaging capacity of wire-cut foam transport case insert by 150% while maintaining identical external dimensions.
• Reduced bearing housing scrap rate during integration of robotic knee joint assembly with a custom-designed bearing press fixture.

Hardware Engineer – UW Autonomous Vehicles Lab          
Jan 2018 – Apr 2018

• Selected and modeled performance of heating units to be attached to vehicle LIDARs and vision cameras in order to expand cold weather performance envelope.
• Designed a cooling system to regulate the temperature of the compute stack in the trunk of the car, and validated a 64% improvement in thermal regulation using computational fluid dynamics (CFD) analysis.
• Created PCB layout to unify three discrete thermal control systems – LIDAR, compute stack, and vision cameras
• Designed a mechanical fixture to better position a target grid utilized by the car’s onboard intrinsic camera calibration system, reducing the number of process operators required by 50%.

Education

University of Waterloo Class of 2020
BaSC Mechatronics Engineering, Honors, Co-Op

Qualifications

Certified SolidWorks Professional (C-WSJR8DBZXN)
US-CAN Dual Citizen
Unrestricted Driver’s Licence