Department of Defense
Project: CVN77 Composite Mainmast
Client: US Navy
Subcontractor: Northrop Grumman - Shipbuilding Sector
Awards: Northrop Grumman Corporation Presidents Award
Project Description: First and most composites intensive structure ever built for a nuclear powered aircraft carrier.
Responsibilities: Managed development, production and installation of all composite components for Northrop Grumman Newport News.
Wrote repair procedures and ran testing program for all composite structural sections.
Project: Los Angeles Class Submarine – Retractable Bow Plane
Client: US Navy
Subcontractor: Northrop Grumman - Shipbuilding Sector
Project Description: Selected maintenance opportunities for submarines requiring inspection and repair of Retractable Bow Planes (dive and surface rudders).
Responsibilities: Engineered and wrote repair procedure for Los Angeles Class Submarine Retractable Bow Plane Tip Seals.
Project: VIRGINIA Class Submarine – High Frequency Chin Array (HFCA)
Client: US Navy
Subcontractor: Northrop Grumman - Shipbuilding Sector
Project Description: The US Navy's newest fast attack submarine requires the use of composite fairings for sonar units.
Responsibilities: Wrote procedures, provided training and on-site oversight of the production of HFCA composite components. Provided technical expertise on-site at the producer of the HFCA in order to train their team to successfully produce the composite components and meet their contractual obligations to Northrop Grumman.
Project: VIRGINIA Class Submarine – Dihedral Pod Cover Plate & Tooling
Client: US Navy
Subcontractor: Northrop Grumman - Shipbuilding Sector
Project Description: The US Navy's newest fast attack submarine utilizes composite fairings for certain classified components. Complex geometries rule out the use of steel for these components.
Responsibilities: Developed a method to create matched tooling from an as-built welded structure in order to create a composite cover plate that would not require any post-machining of the mating surface in order to fit tight gap tolerances.
Project: VIRGINIA Class Submarine – Sail Cusp
Client: US Navy
Subcontractor: Northrop Grumman - Shipbuilding Sector
Project Description: The US Navy requires cost and schedule reductions on their newest fast attack submarine. Complex geometrically shaped fairings take too many manhours to produce in steel and meet flow requirements.
Responsibilities: Developed concept for composite sail cusp to replace the incumbent steel version. From that concept, a foam filled, composite, male molded sail cusp was produced at quarter and full scale.
Project: VIRGINIA Class Submarine – Syntactic Foam
Client: US Navy
Subcontractor: Northrop Grumman - Shipbuilding Sector
Project Description: The US Navy has a requirement for a void filling foam that is low cost, but still meets hydrostatic crush and shock requirements.
Responsibilities: Co-developed, with the US Navy and Penn State University, a Macrosphere Syntactic Foam for void filling of US Navy submarines. Lightweight, low density, commercial off the shelf materials were used to meet all hydrostatic crush pressures as defined by the US Navy.
Project: VIRGINIA Class Submarine – Out of Autoclave Prepreg
Client: US Navy
Subcontractor: Northrop Grumman - Shipbuilding Sector / General Dynamics Electric Boat
Project Description: The US Navy requires a new composites manufacturing process that provides the highest mechanical properties possible, while being a repeatable, robust process that can take place in a shipyard environment.
Responsibilities: Co-developed Integrated Breathing Manufacturing Process (IBMP EB Spec 4601) with representatives from General Dynamics Electric Boat and the US Navy. This process was implemented and approved as the first US Navy specification for out of autoclave prepregs.
Project: USS Monitor Replica – Gun Turret Composite Door
Client: The Mariners Museum (Newport News, VA)
Subcontractor: Northrop Grumman - Shipbuilding Sector
Project Description: The Mariners Museum required access to the turret on a replica of the USS Monitor
in order to store items and use as a bar /serving area for receptions.
Responsibilities: Designed, engineered and fabricated a composite door to mate to the gun turret of a full scale replica of the USS Monitor, built by The Mariners Museum. This door was designed to blend seamlessly with the steel turret, including faux rivets and inside hidden pin hinges.
Industrial
Project: McDonald’s Rebranded Golden Arches
Client: McDonald’s Corporation
Subcontractor: Custom Fiberglass Moldings
Project Description: The McDonald's Corporation has designed a new Golden Arch as part of its rebranding campaign. These arches presented processing challenges as well as challenges to keep birds and rainwater out, due to their architectural design.
Responsibilities: Engineered manufacturing process, selected adhesives for bonding top and bottom shells. Developed efficient manufacturing process to compete, and beat, the cost of production in China. All arches are now built in the USA.
Marine
Project: Powerboat P1 King of Shaves
Client: King of Shaves
Subcontractor: Fountain Powerboats
Awards: World Champion P1 Powerboat
Project Description: Fountain Powerboats has a rich history of designing and building record winning offshore powerboats. The P1 Powerboat World Series is the single most important championship for the P1 level race boats.
Responsibilities: Provided on-site process and engineering expertise during the build of the eventual winner of the 2007 P1 Powerboat World Series. Oversaw all aspects of the hull structure build in epoxy, structural foam core and vacuum bagging operations.
Project: Volvo Open 70 il Mostro
Client: PUMA / PUMA Ocean Racing
Subcontractor: Goetz Custom Boats
Awards: 2nd Place, 2008-2009 Volvo Ocean Race
Project Description: The Volvo Ocean Race is a 39,000 nautical mile race around the world in 70ft custom designed
and built yachts. The purpose of the Volvo Ocean Race is to push sailing and sailors to the limit of both engineering
and boatbuilding technology.
Responsibilities: Served as technical point of contact and oversaw all technical issues and testing during 6 month build of il Mostro.
Project: Volvo Open 70 mar Mostro
Client: PUMA / PUMA Ocean Racing Powered by BERG
Subcontractor: New England Boatworks
Awards: 1st Place, 2011-2012 Volvo Ocean Race In-Port Series / 3rd Place, 2011-2012 Volvo Ocean Race Overall
Project Description: The Volvo Ocean Race is a 39,000 nautical mile race around the world in 70ft custom designed and built yachts.
The purpose of the Volvo Ocean Race is to push sailing and sailors to the limit of both engineering and boatbuilding technology.
Responsibilities: Designed and built hull tooling to extremely tight tolerances. Served as technical point of contact for all aspects of
materials for build process.
Project: Santa Cruz 37
Client: Santa Cruz Yachts
Awards: SAIL Magazine Best New Performance Boat 2009
Project Description: A small group of professionals from around the globe were brought together to give a rebirth to the iconic
Santa Cruz Yachts brand with a new design, utilizing the latest in production boatbuilding technology.
Responsibilities: Contracted as Composites Manager to oversee a build team of 27 composites technicians to build epoxy / carbon fiber
semi-custom racing yachts. Wrote training guides and developed policies and procedures to meet all OSHA, EPA, ISO guidelines. Oversaw
entire build, from initial molding through final assembly.
Project: Huckins 45 Sportfisherman
Client: Huckins Yacht Corporation
Project Description: A custom 45 foot sport fishing yacht manufactured to meet the demands of offshore fishing, fuel efficiency and
luxury.
Responsibilities: Contracted to perform all of the structural composite manufacturing in a purpose built facility in South Carolina.
The hull, deck and superstructure were male molded, bead and cove core and infused skins. The finished project met or exceeded
all contracted requirements.
Project: Blue Jacket 40 Boom & Rudder Post
Client: Island Packet Yachts
Awards: Cruising World Magazine Boat of the Year Domestic Cruiser 2014
Project Description: Lightweight, hollow critical structures manufactured for 40 ft cruising sailboat.
Responsibilities: Manufactured over 10 ships sets of hollow carbon fiber out of autoclave prepreg booms and rudder
posts. Included high tolerance machining and bonding of critical metal components.
Project: Tartan Yachts, Legacy Yachts, Aspire Spars & Components
Client: Tartan Marine Company
Project Description: Contracted as Executive Vice President of Manufacturing for Tartan Yachts to begin
process of turning around the business unit of Hanover Marine, the manufacturing arm of Tartan Marine.
Responsibilities: While overseeing the manufacturing operations and beginning the process of employing
accountable processes and procedures, developed the new commissioning process and procedures for all new
Tartan Yachts. Also during this time 3 new business units were launched in addition to Tartan Yachts (sail yachts).
These were Legacy Yachts (power yachts), Aspire Spars & Components (carbon fiber spars, rudder posts, booms, etc)
and MAE Composites (industrial advanced composites).
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