Brian Christian
Mechanical Engineer
Falcon,CO
Summary
Accomplished mechanical engineer with over 15 years of experience in mechanical design project management and high-reliability systems. Expertise in resolving complex design challenges and leading cross-disciplinary teams from concept to production. Proficient in integrating mechanical and electrical design software, with a strong focus on iterative design and manufacturing. Proven ability to deliver technical reports and coach teams in high-pressure environments, particularly in aerospace and industrial sectors.
Overview
18
18
years of professional experience
1
1
Certification
Work History
Principal
Falcon Prototyping & Machine
02.2017 - Current
- Founded and led consulting, design, and manufacturing firm, delivering full-cycle mechanical engineering services from concept to production for diverse clients, including startups and established businesses.
- Specialized in robotic integration, Design for Manufacturing (DFM), electro-mechanical design, PLC-based automation, and CNC machining, consistently delivering detailed drawing sets for custom components and assemblies.
- Utilized Fusion 360, SolidWorks, and AutoCAD for design, prototyping, and testing of industrial robots and 3D printers, ensuring functionality and performance.
- Developed and implemented QA/QC program based on Lean Six Sigma principles, enhancing quality assurance processes.
Senior Mechanical Engineer
3D Systems
07.2022 - 02.2025
- Spearheaded the full-cycle mechanical design of the Titan EXT800 3D printer, culminating in a patent-pending design for the machine frame, demonstrating ability to take projects from alpha to market.
- Conceived and developed a novel CNC Tool Changer design from loose constraints, leading to a second patent application and showcasing innovative problem-solving in complex mechanical systems.
- Supported $1.5M project by defining 5-axis machine kinematics, designing TCP, and developing post processors, while providing machine support and training, leading to enhanced reliability in existing industrial machines.
- Integrated mechanical designs with control systems and software, validating performance against requirements to ensure alignment with project goals.
Project Manager
Kinder Morgan Corporation
09.2012 - 02.2017
- Guided complex infrastructure projects with budgets up to $40M from business case through design and commissioning, achieving over 95% on-time completion within high-reliability energy environment.
- Led cross-functional teams to deliver projects on time and within budget.
- Developed project plans outlining scope, timelines, and resources needed.
- Managed material procurement and contractor engagement, ensuring regulatory compliance across local, state, and federal levels while overseeing engineering contractors and dedicated staff.
- Coordinated stakeholder meetings to gather input and align project goals.
Operations Supervisor
El Paso Corp. - Colorado Interstate Gas
08.2010 - 09.2012
- Oversaw daily operations of major natural gas hub with 10 pipelines, 4 compressor stations, and 14 compressor units, maintaining high-reliability performance.
- Supervised daily operations to ensure efficient workflow and safety compliance.
- Implemented process improvements for operational efficiency and cost reduction.
- Coordinated team schedules to optimize resource allocation and task completion.
- Conducted interviews, hired, and coached 9 direct reports while effectively managing operational budgets.
Reliability Engineer
El Paso Corp. - Tennessee Gas Pipeline
05.2008 - 07.2010
- Ensured 90%+ unit availability and safety for 11 natural gas compressor stations (100+ engines, 275,000 HP total) in high-reliability energy transmission environments.
- Led nine capital expenditure projects for turbines and reciprocating drivers, overseeing efficiency experiments and new installations.
- Executed over 50 root cause failure analyses (RCFA) to resolve complex timeline and budgeting issues, enhancing FMEA understanding.
Education
Bachelor of Science - Mechanical Engineering
Mississippi State University
Starkville, MSStarkville, MS
Associates Degree - Applied Science
Northeast Mississippi Community College
Booneville, MSBooneville, MS
Skills
- Aircraft systems knowledge
- Avionics integration skills
- Complex assembly design
- Structural analysis
- Harsh environment design
- Design for manufacturing
- Materials science
- Manufacturing processes
- CAD software expertise
- GD&T expertise
- Troubleshooting expertise
- Performance validation
- Integration across disciplines
- Production readiness
- Environmental validation
- Rapid prototyping
- 3D printing applications
- Composite materials integration
- Assembly and testing procedures
- Root cause analysis
- PLC automation expertise
- Robotics proficiency
- Project management
- Mentorship
- High-reliability experience
- 3D printing applications
- Composite materials integration
Certification
- Engineer in Training (EIT/FE), NCEES, Greenville, SC, Currently pursuing P.E. Licensing
- Lean Six Sigma White Belt, AIGPE, Pune, India, Summer 2021
- Licensed Private Pilot (Single Engine Land, Sea, and UAS ratings), Demonstrates direct experience with aircraft and aviation standards.
- Aircraft Restoration & Homebuilding, Restored a WW2 aircraft and currently building own Bearhawk homebuilt aircraft - Showcases deep hands-on mechanical, systems integration.
- Marine Refit, Currently completing a full refit of a 21-ton steel sailing vessel 'Memento Viviere' in Mexico - Highlights extensive hands-on complex mechanical project management, fabrication, international customs, language, and integration skills.
Skills
Complex Assembly Design, Structural Analysis, Design for Harsh Environments, DFM (Design for Manufacturing), Materials Science, Manufacturing Processes, Technical Documentation, Geometric Dimensioning & Tolerancing (GD&T), Rapid Prototyping, Environmental Validation, Production Readiness, Assembly & Test Procedures, Troubleshooting, Custom Component Sourcing, Performance Validation, Mechanical-Electrical-Software Integration, Cross-Disciplinary Problem Solving, Project Management, Technical Guidance & Mentorship, Root Cause Analysis, PLC Automation, Robotics, SolidWorks, Fusion 360, AutoCAD, Aircraft Systems, Avionics Integration, High-Reliability Environments, Oil & Gas Pipelines, Automotive Engineering, Direct full process experience with CNC machining (milling and turning), Electrical Discharge Machining (EDM - Wire and Sinker), Punching, Forming, Cutting, Casting, Mass production and Finishing, Additive Manufacturing and Metal Fabrication
Portfolio
Robot loads and unloads machine
My Portfolio
Timeline
Senior Mechanical Engineer
3D Systems
07.2022 - 02.2025
Principal
Falcon Prototyping & Machine
02.2017 - Current
Project Manager
Kinder Morgan Corporation
09.2012 - 02.2017
Operations Supervisor
El Paso Corp. - Colorado Interstate Gas
08.2010 - 09.2012
Reliability Engineer
El Paso Corp. - Tennessee Gas Pipeline
05.2008 - 07.2010
Bachelor of Science - Mechanical Engineering
Mississippi State University
Associates Degree - Applied Science
Northeast Mississippi Community College