Principal Hardware and Prototyping Consultant

JUN 2025 - PRESENT · 1.3 years

Helping Tech Startups Scale Hardware from Bench to Prototype and Beyond * Translating complex physics, fluid requirements, thermal challenges, and electrochemistry into CAD, custom cell architecture, and hardware builds * Designing custom, low-cost validation test rigs to generate critical degradation and performance metrics for investor milestones. * Establishing early Design for Manufacturability (DFMA) standards to streamline the transition from alpha builds to pilot production.

Principal Hardware and Prototyping Consultant

JUN 2025 - PRESENT · 1.3 years

Helping Tech Startups Scale Hardware from Bench to Prototype and Beyond * Translating complex physics, fluid requirements, thermal challenges, and electrochemistry into CAD, custom cell architecture, and hardware builds * Designing custom, low-cost validation test rigs to generate critical degradation and performance metrics for investor milestones. * Establishing early Design for Manufacturability (DFMA) standards to streamline the transition from alpha builds to pilot production.

Principal Materials Engineer

FEB 2024 - MAR 2025 · 1.2 years

I joined Solvus to lead the development of friction-stir additive manufacturing processes to produce forging-quality, large-scale metal components. We conducted R&D, process engineering, mechanical design, testing, and scale-up in a resource-constrained environment. My role included: Technical Leadership and Engineering --- Owned end-to-end process development from early experimentation through prototype validation. --- Developed overarching test plans to benchmark mechanical properties against traditional forging processes. --- Led problem-solving efforts across characterization, setup, operation, and maintenance of specialized equipment. Business Development --- Facilitated and strategized customer interactions, proposed solutions, and implemented technical milestone targets to keep customers informed of project progress. --- Managed RFP processes with gov't agencies and defense contractors, including comprehensive technical and cost volumes. Manufacturing, Scale-Up, Reliability, and Risk --- Identified and mitigated bottlenecks caused by limited equipment availability. --- Conducted reliability, maintainability, and availability (RMA) analysis on friction stir machines. Specified requirements to maximize machine uptime. --- Led root cause analysis (RCA) and failure mode and effects analysis (FMEA) to address issues and improve robustness of manufacturing processes. Implemented corrective actions to mitigate residual stress effects (FRACAS). --- Partnered with contract manufacturers and large-scale vendors. --- Balanced aggressive timelines with technical rigor and risk management. Engineering Collaboration --- Coordinated parallel development efforts with university partners and external collaborators. --- Worked closely with vendors to expedite repairs, improve responsiveness, and reduce program delays. --- Estimated resource needs and maintained clear, proactive communication with internal and external stakeholders.

Principal Materials Engineer

FEB 2024 - MAR 2025 · 1.2 years

I joined Solvus to lead the development of friction-stir additive manufacturing processes to produce forging-quality, large-scale metal components. We conducted R&D, process engineering, mechanical design, testing, and scale-up in a resource-constrained environment. My role included: Technical Leadership and Engineering --- Owned end-to-end process development from early experimentation through prototype validation. --- Developed overarching test plans to benchmark mechanical properties against traditional forging processes. --- Led problem-solving efforts across characterization, setup, operation, and maintenance of specialized equipment. Business Development --- Facilitated and strategized customer interactions, proposed solutions, and implemented technical milestone targets to keep customers informed of project progress. --- Managed RFP processes with gov't agencies and defense contractors, including comprehensive technical and cost volumes. Manufacturing, Scale-Up, Reliability, and Risk --- Identified and mitigated bottlenecks caused by limited equipment availability. --- Conducted reliability, maintainability, and availability (RMA) analysis on friction stir machines. Specified requirements to maximize machine uptime. --- Led root cause analysis (RCA) and failure mode and effects analysis (FMEA) to address issues and improve robustness of manufacturing processes. Implemented corrective actions to mitigate residual stress effects (FRACAS). --- Partnered with contract manufacturers and large-scale vendors. --- Balanced aggressive timelines with technical rigor and risk management. Engineering Collaboration --- Coordinated parallel development efforts with university partners and external collaborators. --- Worked closely with vendors to expedite repairs, improve responsiveness, and reduce program delays. --- Estimated resource needs and maintained clear, proactive communication with internal and external stakeholders.

Principal Materials Engineer

FEB 2024 - MAR 2025 · 1.2 years

Led team of 6 developing friction stir additive manufacturing (AM) processes to build forge-quality large-scale metal parts for DOD from Al, Ti, and steel alloys. Established specifications and goals with customers, created test plans, sourced metals, led Agile sprints, managed risk, and built cross-functional partnerships.

Senior Engineer

FEB 2022 - NOV 2023 · 1.8 years

I joined Ambri to lead product development and reliability engineering efforts for molten-salt battery seal systems operating in high-temperature, corrosive environments. I served as a bridge between R&D, manufacturing, and supplier partners to improve product robustness. My role included: • Reliability, Testing, and Data Analysis --- Analyzed test data (standard lifespan, accelerated life test), created reliability models, designed and executed structural tests, characterization, and validation protocols. --- Conducted failure mode documentation, material failure analysis, and corrective actions to implement changes to improve seal lifetime (FRACAS). --- Developed environmental stress screening (ESS) test plans including vibration, shock, thermal cycling, and humidity exposure. --- Used DOE, Excel, and JMP to analyze manufacturing and performance data. --- Increased yield by ~20% while reducing costs by ~17% through process optimization to minimize environmental impacts. • Technical Leadership & Engineering --- Taught new teams the design history, new approaches, and the function of seal components. --- Led internal FEA development efforts for new seal designs and materials. --- Aligned full company on seals progress and challenges. • Design, Materials, and Compatibility --- Developed CAD designs and material sets to resolve material-mechanical compatibility challenges. --- Led design reviews of component redesigns and new seal designs --- Addressed corrosion, oxidation, and thermal expansion through targeted redesign and material selection. • Supplier and Quality Improvement --- Identified vendor quality issues related to ceramic sintering variability. --- Worked to shift from ad hoc fabrication toward controlled, repeatable manufacturing processes by leading the team through RCA and DOE activities to identify and solve the problem. --- Improved component lifetime and reduced early failures through data-driven supplier engagement.

Senior Engineer

FEB 2022 - NOV 2023 · 1.8 years

I joined Ambri to lead product development and reliability engineering efforts for molten-salt battery seal systems operating in high-temperature, corrosive environments. I served as a bridge between R&D, manufacturing, and supplier partners to improve product robustness. My role included: • Reliability, Testing, and Data Analysis --- Analyzed test data (standard lifespan, accelerated life test), created reliability models, designed and executed structural tests, characterization, and validation protocols. --- Conducted failure mode documentation, material failure analysis, and corrective actions to implement changes to improve seal lifetime (FRACAS). --- Developed environmental stress screening (ESS) test plans including vibration, shock, thermal cycling, and humidity exposure. --- Used DOE, Excel, and JMP to analyze manufacturing and performance data. --- Increased yield by ~20% while reducing costs by ~17% through process optimization to minimize environmental impacts. • Technical Leadership & Engineering --- Taught new teams the design history, new approaches, and the function of seal components. --- Led internal FEA development efforts for new seal designs and materials. --- Aligned full company on seals progress and challenges. • Design, Materials, and Compatibility --- Developed CAD designs and material sets to resolve material-mechanical compatibility challenges. --- Led design reviews of component redesigns and new seal designs --- Addressed corrosion, oxidation, and thermal expansion through targeted redesign and material selection. • Supplier and Quality Improvement --- Identified vendor quality issues related to ceramic sintering variability. --- Worked to shift from ad hoc fabrication toward controlled, repeatable manufacturing processes by leading the team through RCA and DOE activities to identify and solve the problem. --- Improved component lifetime and reduced early failures through data-driven supplier engagement.

Senior Engineer

FEB 2022 - NOV 2023 · 1.8 years

Technical lead guiding ceramic-metal seal R&D for molten salt batteries including processes, materials, design, quality, and reliability data to endure high-temperature, corrosive, and oxidizing environments. Increased seal production by 63%, collaborated on process changes, and analyzed data to validate designs and processes.

Senior Research Engineer

JAN 2008 - FEB 2022 · 14.2 years

Managed ~30 multi-year, cross-functional engineering R&D programs for NASA, DOE, DOD, NSF, USDA, etc. with $200k-$1M annual budgets. Wrote proposals; worked with gov't clients to develop processes, materials, devices, and integrated systems. Led teams of 2-4 staff. Managed lab safety, compliance, and CapEx.

Senior Research Engineer

JAN 2014 - FEB 2022 · 8.2 years

I led multi-year, multidisciplinary product development programs spanning electrochemical devices, materials, high-temperature assemblies, and integrated process systems across a variety of clients including NASA, DOE, DOD, USDA, NIH, and EPA. We took technologies from concept through functional prototypes, operational demonstrations, and validated systems, analyzing and designing for economic viability. My combined hands-on and management role included (continued below):

Research Engineer

JAN 2008 - JAN 2014 · 6.1 years

Program Management --- Managed $9M+ in funded R&D programs across multiple federal agencies. --- Led cross-functional teams of engineers and scientists. --- Led reporting, milestone deliverables, and stakeholder communication throughout program lifecycles. Business Development --- Led and supported contract proposal efforts, including agency communication, solution inception, IRAD, technical narratives, supply chain assessment, and cost analysis. Systems Design & Engineering --- Designed complete electrochemical and process systems including fluid handling, thermal management, electrical integration, and mechanical assemblies. --- Built and commissioned controlled test platforms involving high-pressure gases, high temperatures, corrosive fluids, and thermofluids. --- Applied DFM principles to ensure systems were serviceable, safe, and scalable. Electrochemical Devices & Materials --- Developed catalysts, membranes, coatings, metallization, epoxy encapsulation designs, and thermoset adhesives. Electrodeposition, copper/silver electrochemistry, thermal materials, --- Designed and validated electrochemical reactors, electrolyzers, and specialized devices for water treatment, gas separation, sterilization, electronics cooling, and energy-related applications. --- New test methods. --- Hardware failure analysis. --- Delivered systems capable of long-duration, failure-free operation in demanding environments. Safety, Risk & Compliance --- Implemented safety protocols addressing flammability, corrosivity, pressure, and temperature hazards. --- Lab management including safety, equipment risk mitigation, and operational procedures across multiple programs. --- Conducted FMEA and other structured risk analyses to support safe system operation.

Senior Research Engineer

JAN 2014 - FEB 2022 · 8.2 years

I led multi-year, multidisciplinary product development programs spanning electrochemical devices, materials, high-temperature assemblies, and integrated process systems across a variety of clients including NASA, DOE, DOD, USDA, NIH, and EPA. We took technologies from concept through functional prototypes, operational demonstrations, and validated systems, analyzing and designing for economic viability. My combined hands-on and management role included (continued below):

Research Engineer

JAN 2008 - JAN 2014 · 6.1 years

Program Management --- Managed $9M+ in funded R&D programs across multiple federal agencies. --- Led cross-functional teams of engineers and scientists. --- Led reporting, milestone deliverables, and stakeholder communication throughout program lifecycles. Business Development --- Led and supported contract proposal efforts, including agency communication, solution inception, IRAD, technical narratives, supply chain assessment, and cost analysis. Systems Design & Engineering --- Designed complete electrochemical and process systems including fluid handling, thermal management, electrical integration, and mechanical assemblies. --- Built and commissioned controlled test platforms involving high-pressure gases, high temperatures, corrosive fluids, and thermofluids. --- Applied DFM principles to ensure systems were serviceable, safe, and scalable. Electrochemical Devices & Materials --- Developed catalysts, membranes, coatings, metallization, epoxy encapsulation designs, and thermoset adhesives. Electrodeposition, copper/silver electrochemistry, thermal materials, --- Designed and validated electrochemical reactors, electrolyzers, and specialized devices for water treatment, gas separation, sterilization, electronics cooling, and energy-related applications. --- New test methods. --- Hardware failure analysis. --- Delivered systems capable of long-duration, failure-free operation in demanding environments. Safety, Risk & Compliance --- Implemented safety protocols addressing flammability, corrosivity, pressure, and temperature hazards. --- Lab management including safety, equipment risk mitigation, and operational procedures across multiple programs. --- Conducted FMEA and other structured risk analyses to support safe system operation.

Process Development Engineer

JUL 2007 - JAN 2008 · 7 months

Process improvements for semiconductor diode manufacturing

Process Development Engineer

JUL 2007 - JAN 2008 · 7 months

Process improvements for semiconductor diode manufacturing

Co-op/Contract Chemical Engineer

MAR 2003 - JUL 2007 · 4.4 years

Electroplating (copper, silver), electrochemistry, surface treatments, embedded capacitor R&D, characterization, and defect analysis for printed circuit boards and solar cells.

Co-op/Contract Chemical Engineer

MAR 2003 - JUL 2007 · 4.4 years

Electroplating (copper, silver), electrochemistry, surface treatments, embedded capacitor R&D, characterization, and defect analysis for printed circuit boards and solar cells.