Engineer Manufacturing

Matthew Berden

Vought Aircraft Industries **** Sanford Rd

**** ****** **** ***********, ** 37135

abnd0g@r.postjobfree.com

abnd0g@r.postjobfree.com

Desk: 615-***-**** Cell: (615) 975-

2663

EXECUTIVE SUMMARY

Mechanical engineer specializing in research and development,

manufacturing, domestic and international patents, and project management.

Over ten years of combined experience in aerospace and automotive fields

with cost and technical reporting, 3D solid modeling, and advanced

structural testing.

EXPERIENCE

Vought Aircraft Industries Nashville,

TN

Materials Technical Officer (MTO) June 2009-

present

Lead engineer and investigator for domestic and international supply

chain

Focal for the Airbus A330 wing assembly line maintaining design

changes and inventory

Manage internal machining offloads, supplier re-bids, and down select

new suppliers

Coordinate engineering changes, manufacturing plans, and quality tags

Develop RFQ packages, enter purchase orders, and manage change orders

Tool/Fixture Design Engineer - Cessna Columbus Wings

Feb.2009-May 2009

Design assembly jigs and tooling using Model Based Definition - CATIA

V5 and Enovia

Model and optimize the entire assembly process using Lean

Manufacturing and Six Sigma

Boeing - Integrated Defense Systems (Military Business Unit)

Huntsville, AL

Ground Based Midcourse Defense Flight Test Engineer

Oct.2007- Jan. 2009

Perform flight test design, radar analysis, pre- and post-flight

system analysis, and risk reduction

System Performance Prediction using hardware in the loop and software

component testing

Boeing - Phantom Works (R&D Business Unit) Seattle, WA

Advanced Structures Engineer: Apr. 2004-

Sep. 2007

Developed multifunctional structures for use in primary, secondary and

tertiary applications

Conducted coupon design, testing (core compression, flatwise tensile,

shear, 3pt bend, tensile)

Modified edge closeout design to strengthen the composite panels by

adding doublers and improve manufacturing methods

Managed the manufacturing scale-up from hand built coupons to

machined large scale components by modeling all tools in CATIA V5 and

outsourcing tooling

Developed QA standard methods for core to skin bond quality using

Through Transfer Ultrasonic (TTU) testing

Published and presented at the 2006 NATO Conference on structural and

RF array development, manufacturing build up, and airframe integration

Designed structural test beds for static, dynamic, and acoustic load

environments

Coordinated with the Air Force Research Labs (AFRL) Dayton to

integrate the test fixture designs with their test facilities

Modeled all designs in CATIA V5, developed BOM and assembly plan

Drafted the manufacturing contract and maintained oversight and

buyoff of the final product

Developed the test plans with stress, acoustic, and AFRL engineers

Authored the test reports and the final report which was submitted to

the AFRL Director

Published and presented at the 2007 SAMPE Conference on design

approach, manufacturing scale up, fixture design, and structural tests

Managed and designed a next generation conformal radar for flight test on

AW&CS

Completed design through installation within the 6 month deadline

from project conception

Coordinated with stress engineering using CATIA V5 solid models to

conduct fatigue, decompression, flight loads, and harmonics analysis

Used DFMA by modeling and machining all fastener holes through use of

a laser positioning device which gave locations and vectors for the

existing structure on the aircraft

Created and completed part and installation drawings in CATIA V4 with

AW&CS signoff

Met all requirements, stress, EMI, QA, and customer signoff for a

successful test

Lead and designed a structurally integrated UHF radar for RF and

structural testing

Designed and manufactured a 10 meter symmetric wing using CATIA V5

from conceptual models in V4

Published and presented at the 2005 SAMPE Fall Technical Conference

on design semantics and manufacturing techniques used to develop the

test fixture under budget

Developed a powered wheel landing gear to lower aircraft emissions, US

Patent 7275715

Integrated an electric motor in the forward landing gear which is

powered by the auxiliary power unit which will save fuel by taxiing

without running the main engines, therefore lowering emissions, wear,

and maintenance

Designed and integrated the motor, gearing, wiring, and hub in CATIA

V5

Conducted trade studies on the power consumption, sizing, and

accelerations required

Drafted language and artwork for patent application

Boeing - Commercial Airplanes Everett, WA

Airplane Certification Engineer Apr. 2003-

Mar. 2004

Certification Specialist for Flight Controls and Electrical systems

Performed Type Certification on the 777-300ER

Reviewed and certified all design changes on twin aisle aircraft with

the Designated Engineering Representative (DER) and the Federal

Aviation Administration (FAA)

Flight Controls Design Engineer Apr. 2001-

Mar. 2003

Production support for the 737 and 757

Updated the quality specification of flight control cables after

conducting a long term study on manufacturing (winding rate, coating

thickness, wire material properties) and its affect on creep combined

with temperature variations throughout the year

Performed tolerance analysis on a control column redesign, and

applied GD&T to control variability in the assembly

Conducted cost saving initiatives for 737 and 757 primary flight controls

Redesigned mounting methods and tooling to attach flight controls to

Monolithic bulkheads

Designed Electro-Magnetically Formed (EMF) torque tubes for flap actuation

(High Lift), US patents 6,932,118 & 7,299,826

Certified for production to replace all torque tube designs company

wide

Performed extensive fatigue testing and analysis to understand the

failure mechanism of high energy rate forming

Designed the mandrel to form the tube without heat treatment,

reducing manufacturing time and cost

Co-authored the Boeing Company Standard: "Assembly of Circular Joints

by Electro-Magnetic Compression Forming"

Developed a new process using Stereolithography to physically model new

designs

Performed physical interference checks with large assemblies

Reduced manufacturing cost, and minimize production time

General Motors Truck Division Milford, MI

Vehicle Development Intern May-Sept.

2000

Test and assembly focal for the "Chinese Blazer" program which

outsourced manufacture of the Chevy Blazer using locally made parts

(engine, tires, electronics, A/C, etc.) for use in the country of

origin

Built beta vehicles for future production by stripping existing

models down and rebuilding with development parts

Created a "Youth Initiative Vehicle" by modifying a GMC Sonoma, which

went into production as a special edition

Syron Engineering Saline, MI

Industrial Automation Tooling Intern May

1999 - May 2000

Developed tooling to assist metal forming operations in the

automotive industry by moving stampings from one die to the next

Tested new and existing designs for reliability with accelerated life

cycle testing to determine reliability of transfer tool mounts,

grippers, vacuum cups, and clamps for use in crossbar, tri-axis, and

end-of-arm tooling

Designed new grippers for hydro-formed tube with wide ranging

tolerances and low friction

Composite Testing and Analysis Ann Arbor,

MI

Material Testing Intern Sept. 1998 -

Jan. 1999

Conducted high temperature, creep, and tensile testing of advanced

nickel metal alloys

Performed statistical analysis based on cross-sectional variations of

the grain structure

Business owned and operated by a professor at the University of

Michigan

U of Mich. Ultrafast Laser Lab Ann Arbor,

MI

Machinist Sep. 1996 - May

1997

Designed mechanisms for optics including oscillators, and adjustable

prism/lens fixtures

Performed vertical end mill and engine lathe operations, and shop

maintenance

PUBLISHED WORK

"Structurally Integrated X-Band Antenna, Large Scale Component Wing

Test", Society of Advanced Material and Process Engineers (SAMPE)

Conference, 6 June 2007, Baltimore MD

"Structurally Integrated X-band Array Development", NATO Research and

Technology Organization (RTO) Applied Vehicle Technology Panel

-141/RSM, 020, 17 October 2006, Vilnius, Lithuania

"Development of a Large Scale Test Bed for Evaluation of UAV

Structurally Integrated Antennas", SAMPE Fall Conference 2005, Seattle,

WA

"Methods of Electromagnetic Forming, Current Applications, and

Development Opportunities" Boeing Technical Excellence Conference 4,

February 2003, Seattle, WA

"Factors Influencing EMF and Fatigue life of Torque Tubes in 2024-T3

AL", Boeing Metals Technology Exchange, June 2002, Long Beach, CA

EDUCATION

University of Michigan Ann Arbor, MI

B.S. Mechanical Engineering Dec. 2000

COMPUTER PROFICIENCY

CATIA V5 -

Over two years experience developing large metallic and composite

structures, test fixtures, and lay-up tooling

Performed rapid prototyping using determinant assembly and DFMA

techniques to minimize construction time

Coordinated directly with suppliers and designers using CATIA output

files for manufacturing

Conducted Finite Element Modeling (FEM) analysis on high stress

parts using the CATIA solid model FEM tool

CATIA V4 -

Two years experience integrating new flight control designs for cost

saving initiatives and production support on the 737 and 757

Created part, assembly, and parts list drawings incorporating

Geometric Design and Tolerance (GD&T) techniques

Excel - Extensive experience as an analyst performing advanced graphing,

statistical analysis, budget estimates, and BOM development

Project - Team lead experienced at planning schedules, link to budgets and

headcount estimates, and contract management

Word - Published author in SAMPE, NATO, and Boeing conferences, authored

white papers, wrote monthly status, test completions, and final reports

for military contracts, developed test and assembly plans

PowerPoint - Experienced presenter at internationally recognized

conferences, lead government contract reviews, and create new methods

of data/graphics presentation for management and customers

EXTRA CURRICULAR ACTIVITIES

Boeing Leadership for Advancement and Development of Engineers (BLADE)

group

Team lead of a group of new engineers 1-5 yr to design, manufacture

and test a rocket launched radio controlled airplane

Teach Boeing process for product development

Develop a schedule and monthly budget by component

Grant Proposal Team for Sci-Quest the North Alabama Science Center (non-

profit)

Currently writing a proposal for an interactive rocket exhibit that

begins by educating students on basic rocket science, combine their

knowledge to design their own rockets, and finally test their rocket

interactively in a rocket simulator.

Develop the technical section and tie the exhibit to educational

goals, and workplace development

Member of the Society of Mechanical and Process Engineers (SAMPE)

Write and present at conferences regarding Boeing R&D

Stay up to date on new material technologies and manufacturing

processes for design and analysis of composite structures, and nano-

technology

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