Meet Our Lead Engineer

Led cost, quality, and manufacturability improvements for Block 4 hardtop through design trades and FEMAP-based composites analysis, reducing labor hours and production risk.

Drove supply chain and manufacturing optimization by qualifying new composites vendors, redesigning layups via hand calculations, and transitioning machined parts to castings through vendor sourcing and process trade studies.

Delivered cross-functional engineering support including high-power DC cabinet design (CAD, busbar layout, structural analysis), marine systems integration at shipyards, and development/execution of NX, Teamcenter, and FEA training programs.

Led mechanical design, analysis, and integration of primary hull structures for Arc One and Arc Sport, owning metallic and composite structures from concept through production.

Drove end-to-end development of Arc Sport systems (requirements, layout, CAD, FEA, testing, and manufacturing integration) in close collaboration with industrial design, electrical, and interiors teams.

Designed and implemented improved composite stiffening structure, reducing manufacturing complexity, cost, and build time while improving production reliability and scalability.

Delivered tooling, jigs, and manufacturing solutions (stringers, hardtop, fixtures), and established internal CAD/drawing/analysis standards to improve engineering quality and efficiency.

Reduced BOM and production costs through supply chain optimization (reshoring, vendor sourcing, composite material strategy) while supporting production ramp, on-site builds, and cross-functional team execution.

Design evolution of the following mechanical engineering projects with the stated results:

• Starship thrust structure (interface from cryogenic tank to engines) for improved reliability, manufacturing and fluids integration leading to a successful development testing campaign of over 800mT of simulated thrust while developing suppliers to fabricate parts at required rate, regular presentation of status to Executive staff and CEO/CTO

• Improved Raptor rocket engine configuration through frequent communication with rocket propulsion, fluids, thermal protection, actuator components teams to enable increased system reliability, manufacturing rate and system commonality 

• Starship flap attachment hardware to react aerodynamic control in flight with integration to hydraulic actuator control hardware, lead installation operation of flap at Texas site

• Electrically actuated Starship payload bay door and associated 4-bar linkage which allows on orbit payload deployment and nose-cone pressurization after deriving requirements from Business Development, Aerodynamics, Thermal and Manufacturing groups, presentation of design to Executive staff and CEO/CTO

• Ten F9 Stage 1 critical subsystems accounting for over $3mill annually to comply with more stringent customer durability requirements including high pressure cryogenic tank passthroughs and propellant management devices, including loads from static, dynamic, CTE, hydrostatic and build tolerance sources, final deliverable of detailed engineering documentation successfully supported NASA certification to fly astronauts

• F9 landing leg bulkhead tank internal structure which reacts static and dynamic landing leg loads for increased load and life capability while reducing cost per build by ~$200k

Supervision of multiple aspects of project design related to the above objectives including design of the parts themselves, review and communication of part fabrication with manufacturing team and suppliers, developing of full testing process including both remotely and on-site at the testing facility, assembly on-site and test implementation

Development of Excel and MATLAB analysis tools and techniques to allow team members to verify Falcon 9 parts have adequate fracture and fatigue life per NASA requirements

Leading technical expert in my department, responsible for documenting systems and processes and training new team members to improve overall onboarding, retention and company efficiencies

Design, analysis and development testing of interface to F9 Stage 1 which allowed the stage to be rolled while landing legs were installed and easily lifted into the transporter

Design, analysis and development testing of interface to F9 Stage 1 which allowed the stage to be rolled while landing legs were installed and easily lifted into the transporter

Design and analysis of all ground support equipment for F9 payload encapsulation, transport and integration to support entrance into commercial market

Launch of integration operations to ensure successful payload integration of the first three commercial F9 launches

Design and analysis of all ground support equipment for F9 payload encapsulation, transport and integration to support entrance into commercial market

Launch of integration operations to ensure successful payload integration of the first three commercial F9 launches