Abraham Thomas
Philadelphia,PA
Summary
Detail-oriented mechanical engineer with expertise in full-cycle product development, thermal management, and finite element analysis (FEA). Led mechanical and thermal design for mass-produced consumer electronics at Comcast—including routers, gateways, and doorbell cameras—with patented innovations in heat sink architecture. Proficient in 3D CAD (SolidWorks, Creo, CATIA, NX), thermal simulation, and DFM for plastics and metal assemblies. Experienced in root cause analysis, reliability testing, and design optimization under aggressive cost, performance, and schedule constraints. Background includes automation hardware design and strong collaboration with electrical, thermal, and industrial design teams to deliver high-quality, manufacturable solutions.
Overview
9
9
years of professional experience
1
1
Certification
Work History
Lead Mechanical Engineer, Product Development
Comcast
Philadelphia, PA
05.2019 - Current
- Lead mechanical and thermal design of high-volume consumer electronics (gateways, routers, doorbell cameras) deployed in millions of homes and businesses
- Inventor of utility patent for innovative heat-sink design to increase WIFI performance
- Thermal analysis and design to keep products within thermal limits and meet regulatory standards
- Optimize product designs for cost, manufacturability, and performance, driving schedule acceleration and quality improvements
- Oversee and guide product managers, offshore design partners, and vendors to ensure technical alignment and successful product execution
- Collaborate cross-functionally with electrical, industrial design, product, and program teams to align on tradeoffs and achieve best-in-class design outcomes
Mechanical Engineer II (Secret Security Clearance)
Cobham Advanced Electronic Solutions
Lansdale , PA
02.2018 - 05.2019
- Lead mechanical analysis and test design engineer for multi-million dollar program, which consists of effectively coordinating analysis and design tasks between engineers and designers
- Assist in all phases of the product-development life cycle for multiple Aerospace and Defense products
- Electronics packaging design to meet military specifications for harsh environments with an emphasis on thermal, CFD, random vibration, and structural analysis
- Lead mechanical engineer for R&D projects including thermal design, analysis, and fabrication of new products for increased cooling capacity of higher power density components
- Lead mechanical engineering support for manufacturing/test equipment design
- Train new engineers in thermal and structural analysis
Mechanical Engineer (Senior Design)
Precision Air Convey Corporation
Newark, DE
09.2017 - 12.2017
- Designed the first automated slab cutting machine for over-sized slabs using PLC, stepper motors, multi-axis actuator, and custom designed 29:1 gearbox
- Electrical Design/Drafting for PLC wiring, stepper motors, drivers, power supply, and voltage regulator
- Automation/Controls programming using PLC programming software
Mechanical Drive Systems Intern
Tesla, Inc.
GigaFactory 1, Sparks, NV
06.2017 - 09.2017
- Designed golden units to calibrate high-voltage battery pack testing equipment, ensuring consistent accuracy across production lines
- Engineered custom actuator attachments to enhance and automate existing manufacturing equipment, improving throughput and operator efficiency
- Implemented critical design modifications to manufacturing pallets to achieve high-voltage electrical isolation and improve safety compliance
- Executed key manufacturing engineering processes including Gage R&R, Poka-Yoke integration, Site Acceptance Testing (SAT), and 5S lean initiatives
- Led battery pack preparation for integration into automated tester lines, collaborating with production and test engineering teams to meet aggressive ramp timelines
Application Engineer 1
Modern Controls Inc.
New Castle, DE
03.2017 - 06.2017
- Designed and compiled detailed controls wiring packages for Building Automation Systems (BAS) using Visio, ensuring accuracy and field readiness
- Automated Visio-based design workflows to streamline drawing creation, significantly improving productivity and consistency across project documentation
Project Engineer
Johnson Controls
Middletown, Delaware
01.2017 - 03.2017
- Managed key aspects of a facility expansion project, applying Lean Manufacturing principles to optimize workflow, maintain budget compliance, and track progress through custom-built spreadsheets
- Designed new equipment layouts and full plant reconfigurations in AutoCAD to support increased production capacity and operational efficiency
- Coordinated with internal stakeholders and external vendors to source and procure new machinery, ensuring technical fit, cost-effectiveness, and timely delivery
Structural Engineering Intern
Siemanowski Consulting inc.
Wilmington, Delaware
06.2016 - 01.2017
- Performed structural engineering analysis and load calculations for residential and commercial buildings, including a multi-million-dollar auditorium project in the Comcast Technology Center
- Created detailed 2D/3D structural models using AutoCAD, RISA 3D, and Revit for code-compliant design and construction documentation
- Conducted on-site field inspections and data collection to validate existing conditions and inform structural retrofit and design decisions
- Participated in professional engineering meetings and collaborated closely with licensed structural engineers to deliver accurate and timely project deliverables
Education
Bachelor of Science - Mechanical Engineering
University of Delaware
Newark, Delaware12.2017
Skills
- Mechanical and Electrical Design
- Research and Development
- Finite Element Analysis: Structural, Thermal, Modal, CFD, and Random Vibration
- Risk, Cost, and Schedule Reduction for products
- Manufacturing and Automation/Control
- Working Experience in PTC CREO/ProE, CATIA, SolidWorks, Siemens NX, AutoCAD, REVit, RISA 3D, RAM, 6SigmaET, ANSYS, Microsoft Office (Word, PowerPoint, Excel)
Skills
- Social Chair, University of Delaware Wrestling Club
- 1st Place Statics Design Project, Sag-wagon
- Volunteer: MLK Day of Service
- MS Walk Fundraiser and Participant
- Varsity Wrestling - 126 lb Blue Hen Conference Champion
- 1st Team Academic All-State Wrestler
- Active member of National Society of Black Engineers (NSBE)
Certification
- Becoming a Product Manager: A Complete Guide - LinkedIn
- Product Management First Steps - LinkedIn
- Artifical Intelligence Foundations: Thinking Machines - LinkedIn
- Artifical Intelligence Foundations: Machine Learning - LinkedIn
- Machine Learning Foundations: Linear Algebra - LinkedIn
Timeline
Lead Mechanical Engineer, Product Development
Comcast
05.2019 - Current
Mechanical Engineer II (Secret Security Clearance)
Cobham Advanced Electronic Solutions
02.2018 - 05.2019
Mechanical Engineer (Senior Design)
Precision Air Convey Corporation
09.2017 - 12.2017
Mechanical Drive Systems Intern
Tesla, Inc.
06.2017 - 09.2017
Application Engineer 1
Modern Controls Inc.
03.2017 - 06.2017
Project Engineer
Johnson Controls
01.2017 - 03.2017
Structural Engineering Intern
Siemanowski Consulting inc.
06.2016 - 01.2017
Bachelor of Science - Mechanical Engineering
University of Delaware
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