David Aylward
Sr Mechanical Engineer
Asheville,NC
Summary
Experienced Senior Mechanical Engineering team lead/ responsible engineer with an expertise in cross functional problem solving, design decision-making, and project management. High proficiency with 3D modeling and Product Life Management software.
Overview
17
17
years of professional experience
Work History
Senior Mechanical Engineer – Spacecraft (S/C) Configuration
Maxar [formerly Space Systems Loral]
11.2011 - 02.2024
- Led Satellite System Configuration designs from concept through assembly with over 15 successfully operating GEO satellites
- Organized and led weekly status meetings identifying and successfully managing program risks, eliminating potential delays in factory schedule
- Organized and led internal and vendor oriented design collaborations focused on real-time problem solving with appropriate subsystem level engineers, leading to comprehensive large-scale design decisions and optimizations
- Coordinated with subcontractors and vendors to verify unit level mechanical compliance, eliminating potential integration issues and maintaining strict manufacturing schedules
- Managed scheduling and budget constraints (included forecasting manpower and outsourcing needs) with on-time and under budget delivery resulting in significant cost-savings
- Praised for presentation of Configuration level designs at Preliminary and Critical Design Reviews attended by customers, peers, and Senior level Executives
- Responsible for all activities of Configuration Mechanical Engineers on my teams (see details of Mechanical Engineer position below)
- Championed lean manufacturing principles with a modernized model based documentation format, leading to increased operational efficiency and reduced waste
- Developed and implemented continuous improvement methodologies to enhance overall team efficiency and productivity levels
- Spearheaded cost-saving initiatives by identifying opportunities for more streamlined design processes and increased quality
- Managed multiple projects simultaneously, prioritizing tasks to meet tight deadlines and exceed client expectations
- Developed innovative solutions for complex mechanical problems, resulting in improved system performance, reliability, and profitability
- Responsible for design compliance with product specifications and standards requirements
- Strengthened foreign vendor compliance by developing and implementing a tightened documentation protocol for information and data exchange, improving communication, eliminating potential errors and redundancies
- Developed specialized software to verify antenna pointing compliance
- Drafted and released task specific work instructions resulting in cost-savings and increased reliability
- Trained, supervised, and mentored junior engineers, providing guidance on design principles and best practices for successful project outcomes
- Troubleshot and diagnosed assembly and integration issues, maintaining factory schedules
- Conducted root cause analyses for recurring issues, leading to long-term solutions that prevented future occurrences
- Provided technical expertise during project planning phases, contributing to a successful manufacturing schedule
Mechanical Engineer – Advanced S/C Configuration
Maxar [formerly Space Systems Loral]
03.2007 - 11.2011
- Collaborated with Structural, Electrical, Antenna, Mechanism, Mass Properties, Propulsion, Attitude Control, Data Handling, Thermal, Environmental, Test, Integration, and Payload engineers to solve complex design problems, meeting or exceeding all system and subsystem level requirements, within budget and scheduling constraints
- Conceptualized, modeled, and detailed the design and integration of Payload and Bus component assemblies
- Conceptualized, modeled, and detailed the design for procurement and integration of RF interconnects (waveguide and coaxial cables) meeting an array of system and subsystem level requirements, maximizing system performance within budget and scheduling constraints leading to repeat customer business
- Conceptualized, modeled, and detailed the design of custom support brackets and environmental shielding (machined, sheet metal, and composite), reducing system complexity and risk
- Drafted, checked, and released high level assembly integration and lower level piece part drawings
- Reviewed Interface Control Drawings and Models and Structural Assembly drawings to verify mechanical compliance, eliminating integration issues
- Designed stowed and deployed packaging of complex mechanically driven antenna arrangements on the S/C body
- Determined and specified mechanical interfaces of reflectors with respect to the S/C body along with the hold down mechanism type, position, and parameters
- Determined deployment mechanism positioning and sequencing for two, three, and four axis deploying reflectors
- Determined and verified deployed antenna configuration compliance with RF pointing and performance requirements
- Determined and verified stowed antenna configuration compliance with launch vehicle and S/C constraints (negotiating with vendors as needed)
- Determined and verified compliance with Structural, Mechanical, Electrical, Thermal, Testing, and Integration requirements
- Evaluated project proposals for commercial and government customers leading to new business
- Performed trade studies determining feasibility of antenna arrangements suites and performance implications of varying Payload configurations maximizing customer and company interests alike
- Conducted R&D efforts towards emerging space based technologies leading to next gen concepts
- Conducted tolerance analysis at system and subsystem levels reducing unnecessary machining costs
- Communicated project requirements and areas for improvement in design review meetings, eliminating expensive mistakes and reducing costs
Skills
ProE/Creo Parametric
PLM Software (TeamCenter)
MS Office
Project Management
Product Development
Design Solutions
Trade Studies
Technical Competency
Collaboration
Communication
Leadership
Ownership
Attention to Detail
Innovation
System Engineering (DOORS)
Organization
Adobe Acrobat
Specifications Review
BOM Management
Mechanism Design
Adapatability
Scheduling
Problem Solving
Design Reviews
Resource Management
Risk Management
Mentoring and Training
Work Instructions
Technical Documentation
CAD Drafting
Piping Design
Cable Design
Waveguide Design
Requirements Review
Requirements Compliance
Feasibility Review
Continuous Improvement
Thermodynamics
Government Requirements
Hardware Planning
On-site Inspections
Troubleshooting
Metal Fabrication
Composite Design
Excel Visual Basic
Photoshop
Matlab
Computational Fluid Dynamics
CATIA Finite Element Analysis
Education
M.S. in Aerospace Engineering -
California Polytechnic State University
San Luis ObispoB.S. in Aerospace Engineering -
University At Buffalo, State University of New York
BuffaloHonors And Awards
- 1st place in the 2005 AIAA RFP VSTOL Engine Design Competition
- Engineering Dean’s List
- US Naval Academy Senatorial Nomination
- SSL Apogee Awards
Activities
- Climate Reality Leadership Core
- Veterans Assistance Foundation – Volunteer
- Medicinal Botany Program Graduate – Regenerative Design Institute, Bolinas, CA
- Yoga Studio - Volunteer
- Soccer & Lacrosse Clubs
- Gardening
- Hiking
- Bicycling
Timeline
Senior Mechanical Engineer – Spacecraft (S/C) Configuration
Maxar [formerly Space Systems Loral]
11.2011 - 02.2024
Mechanical Engineer – Advanced S/C Configuration
Maxar [formerly Space Systems Loral]
03.2007 - 11.2011
M.S. in Aerospace Engineering -
California Polytechnic State University
B.S. in Aerospace Engineering -
University At Buffalo, State University of New York