I have spent most of the last two decades designing products.  I have a vast understanding of DFMA (design for manufacturing and assembly) principles for many manufacturing processes.  I've designed many products that have complex/organic shaping that required extensive surface modeling as well as products that were simpler geometrically but more complex mechanically or electronically.  While not all consulting projects led to products getting released to market, I have had the great pleasure of seeing products I've designed on store shelves or out in the world, and I find that particularly rewarding.

I am comfortable designing in teams that may include Industrial Designers, Electrical Engineers, Software Engineers, Controls Engineers, Human Factors Engineers, or Product Managers.  I have done so successfully in the past, often in a technical lead or project management role myself.

In addition to being an individual contributor for most of my career, over the years my role has grown to include providing more technical guidance and oversight to engineers at all levels.  I regularly participated in brainstorms and design reviews to help keep a variety of projects on track and ensure quality output for clients. 

Design for machining

Design for sheet metal

Design for plastic injection molding

Design for metal casting

Design for polymer casting

Design for extrusions

Design for additive manufacture (3D printing)

Design for assembly

Injection molding mold design

Design for soft goods/textiles

Fastening methodologies

PEMs

Machine screws

Thread-forming screws

Threaded inserts

Thread locking

Engineering plastics

Engineering metals

Elastomers

Hands-on prototyping

Wiring and cabling

Electronic component selection

Cabling

Sewing

Linkage design

Gear design and analysis

Sealing and gasketing

Complex surfacing

Geometric Dimensioning and Tolerancing (GD&T)

Complex tolerance analysis

Finite Element Analysis (FEA)

Ingress Protection

Data analysis

Design inputs development

Patent research and analysis

CAD Modeling

Drawing and manufacturing packages

Prototyping

Testing

Vendor/supplier selection and coordination

Brainstorming

Technical reviews

Proof of concept

Manufacturing coordination

FAI (first article inspection)

Tooling review

Analysis

Cost optimization