DANIEL T. STEPHENS
Huntsville,USA
Summary
Over forty years of experience in quality assurance and control, configuration management, training, development, manufacturing, and testing of space-flight hardware, tactical missile systems, and space launch vehicles. Over ten years of experience in the U.S. Army, honorably discharged at the rank of E5/Sergeant.
Equipped with strong problem-solving abilities, willingness to learn, and excellent communication skills. Poised to contribute to team success and achieve positive results. Ready to tackle new challenges and advance organizational objectives with dedication and enthusiasm.
Organized and dependable candidate successful at managing multiple priorities with a positive attitude. Willingness to take on added responsibilities to meet team goals.
Overview
50
50
years of professional experience
Work History
High Temperature Composites Lead Technician
Amentum
Huntsville, Alabama
04.2013 - Current
- Space Launch System insulation and Core stage team member investigating Artemis I In Flight Anomalies, SpaceX and Sierra Space issues to include
- 1. Investigation covers many areas of Core stage issues to include Artemis II foam bubbling after spray.
- 2. Currently working the ICPSU purge boot assembly, (GSE) where an interference was found during tanking and de-tanking of the fuel for flight.
- 3. Worked on SpaceX Heat tiles applying a ceramic coating which had never been performed with EM personnel. Successfully applied a ceramic coating to heat shields with only the current specification written for Marshall technical applications and coating from an outside manufacturer as guidance.
- 4. Worked on Sierra Space Inflatable Habitat to apply a coating to the durables and then using a spatter gun applying dots so the photogrammetry can be used for measuring expansion during testing to failure of the habitat.
- Supervised team operations to ensure compliance with safety protocols and quality standards.
- Mentored junior technicians, enhancing their technical skills and operational efficiency.
- Implemented process improvements that streamlined workflows and reduced downtime.
Materials and Process Staff IV
United Space Alliance
Huntsville, Alabama
01.2001 - 04.2012
- ARES IX, ARES I and ARES V Launch Vehicles. Managed all paint and coatings related projects for the development of the ARES IX, ARES I and ARES V Launch Vehicles for NASA.
- Space Shuttle Program. Project Lead for all coatings and insulation for the Space Shuttle Booster Separation Motors. Performed process audits for new and current vendor verification. Generated discrepancy reports of materials/coatings not meeting NASA standards. Inspected coatings during down select process for curing times, adhesion and compatibility with other coating systems used on flight hardware. Support the processing and flight readiness for all other Space Shuttle missions. Project Lead at MSFC for Return to Flight for STS-114 (cracked throat issues for the booster separation motors). Conducted internal research and development tasks to improve the flight worthiness of Space Shuttle thermal protection systems and coatings. Insured build process of separation motors correctly reflected engineering documentation to include open propellant grain operations and hardware installations.
Associate Field Engineer/Quality Control
Raytheon Corporation
Jeddah, Saudi Arabia
03.1998 - 01.2001
- Hawk Missile System. Responsible for all aspects of Quality Control for the Phase III modifications and refurbishment of the Hawk Air Defense System. Inspected the pre/post modifications, troubleshot discrepancies, and generate technical field reports. Assisted technicians in the generation of modification work orders, technical manuals, schematics, drawings, and quality control procedures. Inspected wire harnesses, cables, solder connections, chassis modifications of all systems and subassemblies.
Senior Engineering Technician
Thiokol Corporation
Huntsville, Alabama
04.1996 - 03.1998
- Hybrid Rocket Motors. Responsible for all aspects of assembly, test, and post-test evaluation of the 72-inch Hybrid Rocket Motor. Assisted in the development and testing of various nozzle and liner configurations. Assisted in the test planning and development testing for the thermal o-ring systems.
- DC-XA. Constructed composite specimens to support development testing on the McDonnell Douglas Reusable Launch Vehicle DC-XA.
Associate Materials Engineer
United Space Boosters Incorporated (USBI)
Huntsville, Alabama
08.1994 - 04.1996
- Space Shuttle SRB. Investigated, evaluated, and tested all anomalies related to the post-evaluation of the Space Shuttle Solid Rocket Boosters. Assisted lead engineers with the implementation of new designs and repair procedures of individual flight hardware electrical assemblies. Tested and certified new webbing materials for the SRB parachutes. Support mechanical and thermal testing on many different SRB systems and subassemblies.
Senior Mechanical Engineering Technician
Raytheon Corporation
Kingdom of Saudi Arabia
08.1988 - 09.1992
- Improved Hawk Missile System. Responsible for providing advice and maintenance of all mechanical components on the Improved Hawk Missile System. Advised civilian and military technicians on proper maintenance techniques. Designed and monitored the fabrication of special tooling, test equipment, and fixtures. Evaluated existing methods and processes to improve efficiency. Performed these duties at seven sites in the eastern province, including periods of Desert Shield and Desert Storm.
Instrumentation Technician
Wyle Laboratories
Huntsville, Alabama
07.1987 - 08.1988
- Space Shuttle SRB Redesign. Supported the Morton Thiokol Wasatch Division and Marshall Space Flight Center during the execution of the SRB redesign program. Responsible for the installation, calibration, troubleshooting, and repair of all test instrumentation necessary to support the program.
- Titan IV Liquid Motor. Supported Martin Marietta in the installation and operation of the instrumentation required during testing of the Titan IV liquid rocket motor program.
Instructor, USAOMMCS
U.S. Army
10.1976 - 07.1987
- Instructed all ranks of multinational military personnel on the maintenance of the Improved Hawk launcher, loader, radar systems, and test equipment. Provided training on battery level shop operations, integrated system checks, and radar orientation/alignment. Training was conducted at the U.S. Army Ordnance Missile and Munitions Center and School located on Redstone Arsenal in Huntsville, Alabama.
- Section Chief, 4th Ordnance Company. Stationed in Germany, supervised five-men crews during testing, troubleshooting, and repair of all data, power, and special purposes cables for the Improved Hawk Air Defense System. Performed electrical, hydraulic, pneumatic, and mechanical maintenance on the air defense assemblies and subassemblies. Responsible for Nuclear, Biological, and Chemical operations and procedures.
Education
A.S. - Aerospace Technology
Calhoun Community College
01.2006
Skills
- Safety compliance
- NACE/AMPP Coatings Inspector
- Thermal protective systems expertise
- Senior team member in polymer insulation
- Material testing and evaluation
- Attention to detail
Interests
Family, Biking, Hiking, Boating, Hunting, and Skiing
Awards and Honors
Jacobs ESSSA Outstanding Task Award for 2015, United Space Alliance Space Flight Awareness, 2009, United Space Alliance Quest Award, 2002, NASA Group Achievement Award, 1987, Army Achievement Award, 1986, Army Good Conduct Award (3 Times)
Related Experience
- Military:
- Mechanical Systems Repairman (24L)
- Instructor Systems Development Workshop
- Methods of Instruction Workshop
- Contract Quality Assurance Evaluator, (US Air Force Certified)
- Primary Leadership Course
- Class G Solder Certification
- Civilian:
- NACE level II Coatings Inspector
- Certified Solder Inspector (Raytheon Corporation)
- Program Critical Hardware Handler (NASA & USA Certified)
- Explosives Handler Team Lead (NASA & USA Certified)
- Integrated Project Manager (USA)
- Lean Six Sigma
Other Relevant Information
- Health: Excellent
- Security Clearance – Secret (Not current since 2013)
Timeline
High Temperature Composites Lead Technician
Amentum
04.2013 - Current
Materials and Process Staff IV
United Space Alliance
01.2001 - 04.2012
Associate Field Engineer/Quality Control
Raytheon Corporation
03.1998 - 01.2001
Senior Engineering Technician
Thiokol Corporation
04.1996 - 03.1998
Associate Materials Engineer
United Space Boosters Incorporated (USBI)
08.1994 - 04.1996
Senior Mechanical Engineering Technician
Raytheon Corporation
08.1988 - 09.1992
Instrumentation Technician
Wyle Laboratories
07.1987 - 08.1988
Instructor, USAOMMCS
U.S. Army
10.1976 - 07.1987
A.S. - Aerospace Technology
Calhoun Community College