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Summary
This Senior Structural & Mechanical Systems Engineering Consultant is a structural engineer, designer, and mechanical systems engineer with over 46 years of experience. Skilled in structural analysis with NASTRAN, FEMAP, and hand calculations, leading small teams of engineers, and writing technical documents.
Highlights
- NASTRAN
- FEMAP DFM
- Hand Calculations
- Free-hand Sketching
- Technical Writing
- Vibration Testing
- Efficient Design
- Proposal Writing
- Fabrication Techniques
- Material selection
- Communication
- Time Management
- Collaboration
Relevant Accomplishments
- Saved the Cassini Narrow Angle Camera from experiencing a disastrous random vibration test by stopping the test and then discovering and correcting a NASTRAN structural modeling error. Over the next six months, the Camera was redesigned, reanalyzed, and rebuilt leading to a successful random vibration test campaign.
- Pioneered the usage of 3D printed Ultem plastic components for use on all flight missions lab-wide by creating and executing a qualification test campaign for the SPHEREx Thermal System.
- Developed a unique way of qualifying a large structure for SPHEREx for static load factors utilizing a sinusoidal sweep methodology and multiple accelerometers to monitor resulting accelerations.
- Analyzed the windsock mechanism for strength and stiffness for the first robotic rover on Mars (Sojourner) including latch loads.
- Optimized and strengthened design of honeycomb panel radiators and solar panels based on the core shear loads from a detailed finite element model.
- Analyzed and documented instruments across dozens of missions like the Drop Physics Module aboard the ISS, Mars Pathfinder, Venus Probe, and Stardust.
- Helped to design, then modeled, analyzed, and tested dozens of Ground Support Equipment (GSE) fixtures (test fixtures, lifting rigs, assembly fixtures, etc.) on the SPHEREx project. All GSE fixtures were made on time and under budget.
- Led the design, structural analysis, production, and testing for a dual cryo-cooler instrument that needed to be structurally isolated. The schedule for going from an initial concept to a completed and structurally verified instrument was a very fast 9 months.
- Led the creation and monitoring of system requirements and converted them to specific mechanical and thermal requirements that could be well understood, tracked, and verified for the SPHEREx Project.
- Developed a consistent set of interfaces for the Space Interferometer Mission Instrument to the Spacecraft Bus. Made sure that the Interface Control Document was maintained throughout the design process ensuring no interface issues downstream.
- Developed detailed instructions for assembly, integration, and testing of flight hardware for the SPHEREx project, and other flight programs often included helpful images from drawings or solid models.
- Oversaw key design reviews for the Space Interferometer Mission (SIM), SPHEREx, and many more projects.
- Worked with dynamicists to reduce the stringent initial loads provided at the beginning of projects as needed on multiple missions.
- Developed the requirements, wrote the technical portion of the contract, developed criteria for milestones, monitored progress, held monthly reviews, oversaw testing, and wrote the final report for the contractor as the Contract Technical (CTM) for the Isolation System (ISOS).
- Designed and analyzed a complex vibration test fixture under stringent mass and stiffness requirements that bridged two test shakers over eight feet apart.
- Performed analyses on a set of missile circuit boards and recommended modifications for strength and survival, leading to a successful random vibration test that exhibited over 500 G’s.
- Provided the design and analysis for a large cooling fan to be retrofitted into an old wooden structure under restrictive installation conditions. The fan continues to operate with optimal performance.
- Created a complex structural analysis model of a dual steering column for a jet plane (over 250 discreet parts). Analysis identified over a dozen parts that needed to be modified for strength. Consulted and approved the updated design that led to successful vibration testing.
- Led the prototyping process for a unique, light-weighted bicycle pedal used for racing accounting for cost, DFM, and schedule.
Roles
- Owner
- Engineer
- Analyst
Request Expert / Similar Expert
Click “request expert” for a free initial screening call with this expert or a similar expert regarding your expert consulting needs
To apply for this job email your details to haleymmagnani@gmail.com
