SENIOR STAFF DESIGN ENGINEER Resume Example HYPERTHERM INC

SENIOR STAFF DESIGN ENGINEER

Experience

SENIOR STAFF DESIGN ENGINEER, 10/2017 to Current
HYPERTHERM INC – HANOVER, NH

Managed development of 105A Cut, 105A Gouging and FineCut Processes and Commercialized achievement from cartridge technology project into new generation plasma cutting cartridge.
Managed cartridge process M5 validation from test definition to completion.
Coordinated with cross-function teams from manufacturing, quality, and procurement to ensure part delivery.
Monitored test progress with technicians.
Led project on cartridge lot certification for validation tests.
Confirmed cartridges accuracy from component manufacturing, cartridge assembly, production verification, to test completion.
Finalized nozzle-swirl ring crimping spec for cartridge releasing with collaboration with DE, QE and MPEs.
Identified root causes of key issues from field trial, executed key decision on design improvement to achieved highest product robustness from cartridge dropping failure.
Coordinated with external vendors and internal teams to solve over-molding issues to secure production of swirl rings.
Achieved final decision on nozzle print with successfully negotiation among MPE, DE and management without sacrificing high standard of cut quality.

STAFF DESIGN ENGINEER, 04/2014 to 10/2017
HYPERTHERM INC – HANOVER, NH

Led architectural design of an industrial game-changing plasma cutting torch and cartridges.
Built a product platform for next generation by adapting non-traditional manufacture and assembly method in the plasma cutting industry.
Defined research strategy and executes technology project development, obtained in 80% of cost reduction for BOM of consumables.
Managed design for manufacturing (DFM) projects for high-temperature plastics molding, deep draw stamping components from prototype, validation, to production.
Design for Assemblies (DFA) for system level automatic assembly line for both low volume and high-volume plasma cutting consumable with automation supplier.
Created non-traditional plasma cutting swirl ring design adapting high-temperature plastics molding.
The design reduced 80% of piece part cost, also established the core foundation for next generation product.
Created stamped shields and codeveloped a hybrid stamping/cold forming process for a shield thickness ratio of 1:4, which broke the stamping industrial standard and achieved 90% cost reduction.
Mentoring plasma process engineers and intern to developing their plasma process expertise for production development.

PLASMA PROCESS ENGINEER, 03/2009 to 04/2014
HYPERTHERM INC – HANOVER, NH

Led technology development project and carried through production launch of a world-leading handheld plasma cutting product, Powermax 125 plasma cutting system.
Established a torch with outstanding cooling efficiency by effectively managing cooling flow path, resulted in 50% increase of electrode life.
Generated a uniform gas distribution system for torch and consumable, which increased 20% longer consumable life, 10% higher cutting speed.
Developed a hand cutting shield with diverging shape castellation, reduced 94% of build- up and increase more than 10 times of shield life.

R&D INTERN, 05/2008 to 10/2008
CORNING INCORPORATED – CORNING, NY

Identified root cause of ceramics deformation in microwave drying process.
Developed multi- physics COMSOL FEA simulation on microwave drying process.
Proposed improve microwave oven design to achieve uniform energy dissipation and eliminate ceramics deformation.

Accomplishments

Cost Effective Cartridge for a Plasma Arc Torch, US20160050740 A1.
Swirl ring and contact element for a plasma arc torch cartridge, US10335888B2.
Consumable cartridge for a plasma arc cutting system, US9981335B2.
Wide bandgap semiconductor based power supply assemblies for plasma operating systems and related methods and devices.
US 20150282290A1.
Devices for gas cooling plasma arc torches and related system and methods, US 8698036 B1.
Plasma ARC Torch Electrode with Symmetrical Plasma Gas Flow, US9480139 B2.
Apparatus and method for securing a plasma torch electrode, US20150021300A1.
Failure event detection in a plasma arc torch, US20120234803A1.
Diffuser Shape Vent Slots in a Hand Torch Shield Castellation, US8835796 B2.

Education

PHD: 05/2009
ELECTRICAL ENGINEER, CLARKSON UNIVERSITY - NY

Numerical and experimental research on magnetic material core losses for electrical motor.
Developed a novel analytical core loss formula, which was applied into industrial machine design software at Black & Decker.
Developed a finite element (C++) model on non-liner (hysteresis) magnetic materials, predicted accurate core losses for wide frequency and thickness range.

M.S: PLASMA, 08/2005
DALIAN UNIVERSITY OF TECHNOLOGY - DALIAN

Research on plasma physics with numerical simulation.
Built the first full frequency scale model for boundary-varying radio frequency sheath, obtained accurate ion energy distribution.
Combined a molecular dynamic and a ﬂuid sheath model for dusty plasma void, discovered electrical field in electrode center formed the dust void.

Summary

Architecture (mechanical) engineer with 12+ years' Leading product development experience, with track record of product delivering from concept through market, awarded 60+ patents worldwide, pursuing a Lead Engineering Role which utilizes my critical engineering mind, multi- physics background, project management experience to advance my career.

Publications

SELECTED PAPERS
Y. Zhang, et al., “Magnetic Characteristics and Core Losses in Machine Laminations: High Frequency Loss Prediction from Low Frequency” IEEE Tran Ind. Appl., 48, (2), 2012
Y. Zhang, et al, “A Novel Hysteresis Core Losses Model of Magnetic Laminations”, IEEE Trans. Energy Convers., 26 (4), (2011).
Y. Zhang, et al, “High Order Finite Element Model for Core Loss Assessment in a Hysteresis Magnetic Lamination,” J. Appl. Phys., Vol. 106, 043911 (2009).
Y. Zhang, et al, “Formation of a cylindrical dust void in a plasma crystal due to a potential bump”, Phys. Rev. E 78, 016405 (2008).
Y. Zhang, et al, “Characteristics of a plasma sheath in a radio frequency biased voltage”, Phys. Plasmas 11, 3840 (2004).

Interests

Basketball, Hockey, Taiji, Yard work

Highlights

High pressure/high temperature
Root cause analysis
Plastic molding/Sheet metal stamping
Plasma Research and Development
Design of experiments
Failure mode and effect analysis (FMEA)
Solidworks
Project management
Design for manufacture and assembly
Mechanical design and GD&T
Metal stamping
Model and Simulation (FEA, CFD)
Flow / Thermal management
Thermodynamics
Multi-physics engineering
Architectural design, Radio

Automation, Research
C++, Simulation
Draw, Solidworks
Cost reduction, Strategy
Delivery, Validation
Design of experiments
Design software
Product Development
Managing
Materials
Mechanical design
Mentoring
Microwave
MPE
Negotiation
Next
Novel
Physics
Processes
Procurement
Progress
Project development
Project management
Quality

Resume Overview

Companies Worked For:

HYPERTHERM INC
CORNING INCORPORATED

School Attended

ELECTRICAL ENGINEER, CLARKSON UNIVERSITY
DALIAN UNIVERSITY OF TECHNOLOGY

Job Titles Held:

SENIOR STAFF DESIGN ENGINEER
STAFF DESIGN ENGINEER
PLASMA PROCESS ENGINEER
R&D INTERN

Degrees

PHD : 05/2009
M.S : PLASMA , 08/2005

SENIOR STAFF DESIGN ENGINEER Resume Example

Resume Score: 80%

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