MICHAL WARZECHA
El Dorado Hills,USA
Summary
Innovative Mechanical Designer experienced in manufacturing machinery, tooling, and electrical systems. Delivered robust designs for aircraft nacelles, rocket engines, and explosive systems while conducting thorough structural and thermal analysis using classic and digital methods. Committed to advancing manufacturing processes for solid rocket motors.
Overview
36
36
years of professional experience
1
1
Certification
Work History
Principle Electromechanical Engineer
Northrop Grumman
McClellan, USA
04.2024 - Current
- Led team to develop and design data collection electrical chassis using NX/CPLM, incorporating internal printed wiring board (PWB).
- Integrated EMI shielding and connector mounting features to enhance device performance.
- Designed data cables for Siemens Capital, including soldering, multicore configurations, pinout arrangements, heat shrink application, and braiding.
Electrical Engineer (Contract)
Mindlance Inc (Cummins Accelera)
West Sacramento, USA
03.2022 - 03.2024
- CREO/PROE, Designed prototype electrical power cables for hydrogen fuel cell commercial semi-trucks and utility vehicles.
- Worked with fabrication team on installation, troubleshooting, ergonomics, improving designs, and build instructions.
- Developed ePTO (export power) modules.
- Coordinated with aluminum casting suppliers to optimize manufacturing processes and facilitate seamless vehicle integration.
Solutions Engineer (Contract)
InfoTree Service Inc (Siemens Mobility)
Sacramento, USA
09.2019 - 03.2022
- Development and design of locomotive and coach components (Amtrak and VIA Rail)
- Drafted 2D and developed 3D solid models (CREO PROE v4.0, CREO VIEW, PDM) for electrical systems, wheelchair access mechanisms, sheet metal racks, cabinet components, frames, electrical busbars, and structural mounting hardware.
- Selected materials and vendors for components, prepared Bill of Materials (BOM), and coordinated with structural analysis and manufacturing teams to ensure alignment with design specifications.
Senior Tooling Engineer
Aerojet Rocketdyne
Sacramento, USA
05.2004 - 09.2019
- Designed various tools including welded structures, remote robotic propellant trimming systems, rocket motor and hydro-proof test stands, rocket nozzle inverters, munitions casting equipment, explosive pellet dies, warhead transportation systems, and large hydro-proof test fixtures.
- Coordinated entire process stream: contract proposals, initial and final design (CAD), stress analysis (FEA), tool coordination and fabrication with internal and external suppliers, operational checkout, and repairs.
- Designed aerospace manufacturing machinery, tooling, and structures.
Senior Engineer
Goodrich UPCO
Fairfield, USA
06.2003 - 05.2004
- Designed, built, and tested aircraft explosive egress systems to enable rapid crew escape.
- Led engineering teams to design innovative aerospace solutions at Goodrich UPCO.
- Developed project timelines and technical specifications for various aerospace projects.
- Collaborated with cross-functional teams to enhance product development processes.
Contract Mechanical Engineer
Entegee Inc (Goodrich De-Icing Division)
Uniontown, USA
12.2002 - 06.2003
- Wrote qualification test requirements and reports for aircraft water systems.
- Coordinated design requirements with vendors and customers to align project specifications and timelines.
- Produced AUTOCAD 2-D layouts of tank assemblies, facilitating accurate manufacturing and assembly processes.
Engineering Specialist
Aerojet Rocketdyne
Sacramento, USA
07.2001 - 11.2002
- Contributed to NASA 2nd Generation Reusable Launch Vehicle (COBRA) development.
- CAD designed over 1000 lb single cast pressurized pre-combustion chamber for 560k lbs thrust Lox Hydrogen rocket engine, enabling advanced propulsion capabilities.
- Collaborated with cross-functional teams on project design and implementation.
Senior Mechanical Engineer
FiberCycle Networks Inc
Roseville, USA
02.2001 - 05.2001
- Conducted mechanical design and thermal analysis (CFD and wind tunnel) for high density, low power web server (Web Bunker 206I) to optimize performance and thermal management.
Hardware Design Engineer / Manufacturing Engineer
Hewlett Packard
Roseville, USA
10.1995 - 02.2001
- Developed server chip attach manufacturing processes and conducted root cause analysis (RCA) of chip attach failures to enhance production reliability.
- Overseas supplier coordination (Aguadilla, Puerto Rico).
- Audited and qualified Contract Manufacturing (CM) repair processes.
- Hardware Development Engineer (10/95-10/99): Thermal Analysis, CFD modeling (Flotherm and MacroFlow), and acoustical testing of enterprise server cooling systems.
- CAD (Solid Designer, ME30) design of sheet-metal chassis.
- Mentored new hires and college students.
- Recruited at local and out of state universities.
Payload Engineer / Propulsion Design Engineer
Boeing
Everett, USA
09.1990 - 10.1995
- Propulsion Design Engineer (3/92-10/95): CAD (CATIA) designed and integrated 777-nacelle hardware (formed parts).
- Coordinated interface requirements with Rolls Royce, ensuring alignment on design specifications and integration for 777-nacelle hardware.
- Developed test plans, selected test instrumentation, and executed ground tests for engine inlet hardware to validate performance standards.
- Led the inlet de-icing system Tiger Team.
- Payload Design Engineer (9/90-3/92): CAD (CATIA) design of composite interior bulkheads and partitions for airline customers.
Education
Master of Science - Mechanical Engineering
University of Washington
Seattle, WABachelor of Science - Aerospace Engineering
University of Michigan
Ann Arbor, MISkills
- Project Management
- Proposals
- Scheduling
- Overseas Coordination
- Procurement
- Recruitment
- Communication
- Team Presentations
- Trade Studies
- Public Speeches
- Lectures
- Machinery operational checkouts
- Current CAD
- ProE/Creo
- CREO VIEW
- Unigraphics NX
- Previous CAD Experience
- CATIA v4
- Solid Designer
- ME30
- AUTOCAD
- FEA
- ALGOR v20
- ANSYS 18
- Design for Manufacturability (DFM)
- GD&T Proficient
- BOM creation
- CFD and Thermal
- Flotherm
- MacroFlow
- Testing
- Thermal
- Wind Tunnel
- Acoustical
- Explosive
- Microsoft
- Word
- Excel
- PowerPoint
- Project
Certification
• California Professional Engineering License (Mechanical) #39618
• FCC Extra Class Amateur Radio License, Callsign WA6RZ
• FCC Extra Class Amateur Radio License, Callsign WA6RZ
Accomplishments
- Solar System Ambassador for NASA / JPL
- 2013 Aerojet STEM Employee Volunteer of the Year (Holy Trinity School Robotics Coach)
- Co-authored patents: 6,496,386 (Circuit Board Shielding) and 6,728,099 (Hybrid Electrical Component Cooling)
Languages
Polish
Limited
Timeline
Principle Electromechanical Engineer
Northrop Grumman
04.2024 - Current
Electrical Engineer (Contract)
Mindlance Inc (Cummins Accelera)
03.2022 - 03.2024
Solutions Engineer (Contract)
InfoTree Service Inc (Siemens Mobility)
09.2019 - 03.2022
Senior Tooling Engineer
Aerojet Rocketdyne
05.2004 - 09.2019
Senior Engineer
Goodrich UPCO
06.2003 - 05.2004
Contract Mechanical Engineer
Entegee Inc (Goodrich De-Icing Division)
12.2002 - 06.2003
Engineering Specialist
Aerojet Rocketdyne
07.2001 - 11.2002
Senior Mechanical Engineer
FiberCycle Networks Inc
02.2001 - 05.2001
Hardware Design Engineer / Manufacturing Engineer
Hewlett Packard
10.1995 - 02.2001
Payload Engineer / Propulsion Design Engineer
Boeing
09.1990 - 10.1995
Master of Science - Mechanical Engineering
University of Washington
Bachelor of Science - Aerospace Engineering
University of Michigan