Senior Mechanical Engineer
Amazon Web Services (AWS)
-
Identified a design improvement that will enable a 1% increase in IT capacity and a 54% reduction
in power consumption at existing data centers; which will result in an estimated $207M savings over 5-years
-
Delivered on multiple projects that have helped data centers run more efficiently, with improved
resiliency & with increased power density
-
Implemented an improved filtration solution that led to reduced Operations effort, 13% lower power
consumption and an estimated $6M savings over 5 years
-
Developed a filter maintenance tool that helps Operations teams to monitor predicted filter life.
This visibility improves preparedness for seasonal weather events like dust storms which reduces
the risk of failures during such events
-
Led the mechanical and thermal design for a new power shelf platform for racks. The new platform
provides 40% higher output power within the same footprint, enables interoperability of multiple
modules within the same chassis and optimizes airflow usage based on load conditions
September 2020 - Present
Senior Design Engineer
Acuity Brands
-
Led & managed cross-functional teams through product development projects from concept through production
-
Leveraged FEA tools, materials analysis & vibration testing to identity changes that improved the designs of 4 different
structural support arms to meet 3G vibration requirements (initial 1G rating) in an expedited 3 month timeline
including die-cast tool changes. Designed novel sheet metal structural support to distribute loads from weaker areas of
the enclosure casting to stronger areas resulting in a solution with no tooling change (saving cost & time)
-
Developed a new heat sink design that increased heat dissipation by 50% within the same footprint, resulting in a 150%
increase in lumen output of light fixture
-
Created die-cast enclosure designs to package electronics & ensure effective thermal management while also meeting
IP66 sealing requirements; Designed a unique gasketing solution with mechanical stops to seal along a curved interface
-
Integrated optics, LEDs & structural components with precision to meet lighting, aesthetic & structural needs; Leveraged
gasket materials & mechanical features to minimize tolerance effects & maintain precise optic locations during assembly
-
Designed components with multipurpose features to ensure ease-of-manufacturing, saving material costs & cycle time
-
Created innovative product designs with high-quality aesthetics using experience with castings, injection molding,
extrusions, sheet metal fabrication, gasketing & electronics packaging
-
Evaluated & addressed field failures using root cause analysis, engineering analysis, testing & statistical data analysis
-
Managed schedules, budgets & project activities through concept design, prototyping, testing, validation & launch
-
Led the effort to create a standard work (SOP) for “Analysis based design” ensuring future designs leverage engineering
tools like FEA to avoid costly re-designs and delays during testing & validation phases
-
On-boarded & mentored engineers in the company’s Leadership Program
August 2018 - September 2020
Mechanical Design Engineer 2
Weil-McLain (SPX Corporation)
-
Managed cross-functional teams to design innovative consumer heating products & components; 2 patents
-
Developed a new heat exchanger design using research data from PCB heat-sinks. The new design attained a 25% physical size reduction & material cost savings
-
Designed new product enclosures using plastic snap-fits & metal extrusions for 6 different product lines that led to a 10% reduction in manufacturing cycle time, ~40% reduction in field installation time & improved aesthetics
-
Led the development of a new grille design starting with multiple industrial design concepts which were quickly narrowed down using heat transfer & fluid flow analysis (CFD) and FEA studies. Worked with manufacturing teams & suppliers to ensure design for manufacturability (DFM) while also maintaining the aesthetically pleasing & functional product needs.
-
Led the design & construction of a configurable testing chamber inside a Cold Room to effectively test heating products of various types in multiple simulated applications & environmental conditions. The chamber's modular design enabled quick test volume adjustments while also providing three separate temperature controlled areas to simulate real world home layouts.
-
Developed business case & acquired company’s first 3D printer helping to expedite product development timelines by 15%. The success of the initial investment led to acquiring an additional printer for more accurate & functional prints
-
Developed HVAC products using design experience in sheet metal, plastics, metal extrusions, PCB packaging/integration and product/system design.
-
Led the development of a comprehensive integrated Controls platform & Connectivity strategy across multiple product lines. Created a unique control board (PCBA) design that could replace electro-mechanical controls on over 30 product lines while maintaining existing features & adding new energy saving & ease-of-use features.
September 2013 - August 2018
Product Developer Engineer
Ingersoll Rand-Trane Residential Solutions
-
Designed innovative heat exchanger features leading to 20% increase in heat transfer coefficient & a smaller heat exchanger with cost savings
-
Airflow Subsystem Leader: Planned & executed the design & development of gas furnace platform’s airflow subsystem
-
Minimized development testing time by creating a simulation tool using excel to evaluate airflow performance of multiple blower-heat exchanger combinations using baseline test data & airflow equations
-
Leveraged CFD to optimize blower placement inside the furnace cabinet for optimized airflow & heat transfer
-
Designed low-cost & reliable slide-out blower attachment for easy in-field maintenance & replacement
-
Developed innovative design solutions: Inventor on 3 patents; 2 designs under internal patent review
-
Managed CTQ analysis, product design, risk analysis & testing for multiple HVAC product updates.
January 2013 - September 2013
Design Engineer
Ingersoll Rand-Trane Residential Solutions
-
Managed the design, optimization and testing for evaporator coils, sheet metal cabinets, air-conditioner components, fans, electronic control housings, and plastic/composite components
-
Led 3D modeling & prototyping of critical component redesigns for productivity and reliability projects
-
Managed entire product life cycle of two new furnace product lines launched within an accelerated three-month timeline using Pro/Engineer and Windchill/PDMLink; Received Chairman’s Award.
August 2011 - January 2013