DESIGN. ANALYZE.
CERTIFY.

Designed the structural provisions to mount an Iridium satellite phone dock inside the cockpit of a Beechcraft King Air 350 and the mounting provisions of a transceiver controller for the installation of several UHF and 433 MHz antennae on a Beechcraft C90. Generated the structural substantiation for the antenna installations onto the aircraft skin using classical hand analysis and wrote the engineering orders for the phone dock wiring and mounting assembly. All EOs approved via FAA DER 8110-3.

Built a detailed finite element model of a door assembly to evaluate frame stresses under a 600 lb applied load at eight discrete locations around the perimeter. Initial analysis of the 0.063" frame showed stresses exceeding allowables, with corner load cases causing the opposite side to lift off the mounting angles. Recommended and verified a thickness increase to 0.084", which brought all stresses within acceptable limits for 2024-T3 aluminum.

Built a solid-element finite element model of a potable water heater assembly to verify structural integrity under 189 psi burst pressure. The assembly used a threaded cap with a seal against the bottle housing - no mechanical fasteners - so the entire model relied on contact interfaces to correctly capture the load path through the threaded cap-to-bottle interface, ring seal, and band clamps. Ran configurations with and without internal ribs to evaluate their contribution to load carrying. Peak principal stresses concentrated at the ring seal and cap interface.

Authored full EO and SSR packages for a series of engine inlet lip skin repairs across a regional airline CRJ-550 fleet (PN CN621-0101-001). Corrosion blend-outs exceeded SRM allowable limits on compound-curvature aluminum lip skins. Substantiated each repair by back-solving for maximum applied loads using an SRM-approved repair splice methodology, demonstrating positive margins despite the out-of-limits material removal. Each package included detailed repair instructions and static strength substantiation per Bombardier CRJ-550 CMM and SRM.

Authored the engineering order and structural substantiation for a cracked web and lower cap angle on a B727-200 wing-to-fuselage fairing support beam at STA 870 LBL 60. Repair involved trimming the damaged web section, installing a 2024-T3 Clad web doubler and filler, and splicing the 7075-T6 lower cap angle with nested L-angles. Classified as a major repair on secondary structure per SRM 51-00-04.

Developed a custom Femap API macro that automates the creation of Modified Huth CBUSH fastener joints between shell mesh layers. The tool supports three mesh connectivity methods - RBE3-CBUSH-RBE3, CBUSH-to-RBE3, and node-to-node - and six Huth joint types covering bolted and riveted joints in metallic, graphite, and hybrid stackups. It automatically extracts plate thicknesses and moduli from the FEM, computes shear and axial stiffnesses per Modified Huth equations, creates the CBUSH properties, orients the elements, and optionally groups the output. Handles batch runs across hundreds of fastener lines in a single execution.

Authored the full engineering data package for exterior livery removal and application on a fleet of DHC-8-400 (Q400) aircraft. Deliverables included an EASA-approved service bulletin, design report, multi-sheet engineering drawings covering plan, side, and front views of the fuselage, wings, H-stab, V-stab, nacelles, and tail cone, plus build standards for multiple livery schemes. Package defined all paint zones, registration marking locations, emergency exit stencils, decal sectioning for the tail logo, and titanium nacelle surface preparation procedures. Maintained through 12 design report issues across multiple operators and paint systems.