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SENIOR STAFF DESIGN ENGINEER Resume Example

Resume Score: 80%

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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
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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

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