Robert Forsyth

• Designed and developed custom biotechnology and clean-room equipment for pharma GMP, contamination-control, and clean-room standards. Produced production-ready 3I to ensure accurate builds, compliance, and on-time delivery.
• Key Accomplishments Vertical Lift Pass-Through Chamber Redesign: Led redesign of vertical lift pass-through chamber, implementing a full mechanic locking system that improved reliability and reduced field service time by ~300%.
• Portable Containment Glove Box for U.S. Military: Engineered custom portable containment glove box, delivering a compact 4 ft x 4 ft x 4 ft system with top-mounted glove port for enhanced compatibility.
• Developed fabrication packages, BOMs, assembly documentation, and manufacturing instructions for internal/external Swagelok quick-connects and integrated forklift pockets for safe transport.

• Led mechanical design and development of biotechnological housing for high-temperature UVC PCB integration, enhancing product reliability. Developed comprehensive fabrica
• Teledyne R&D Division: Designed lightweight aluminum optical housing structures for i R&D teams to develop robust, manufacturable designs meeting performance and reliability
• Designed electromechanical systems for various applications in engineering projects.
• Developed prototypes and conducted testing to ensure functionality and reliability.
• Collaborated with cross-functional teams to integrate mechanical and electrical components.

• Lead Mechanical Engineer, working in new product design of Phase II Launcher & Control Servei Redesigned and developed new products for Phase II Launcher & Control, focusing on short delivery timelines Applied FEA (SolidWorks) and analysis tools to ensure designs met application requirements Facilitated rapid prototyping of designs, enabling proof of concept for sheet metal and 3D printed parts while collaborating with procurement
• Designed mechanical components for various applications in consumer electronics.
• Collaborated with cross-functional teams to optimize product performance and reliability.
• Conducted failure analysis to identify root causes and implement corrective actions.

• Developed military simulations for helicopter pilot trainers, enhancing accuracy of displays and controls. Sheet Metal, EM, Machined, 80/20 Construction, Transport Cases.
• Designed innovative mechanical systems for diverse military and commercial applications.
• Led cross-functional teams to enhance product development and project execution.
• Evaluated product designs for manufacturability and compliance with industry standards.

• Developed military simulations video flight station trainer with 6x 32" visual display units and audio controls, ensuring compliance with security protocols for sensitive military information access.
• Designed hardware components for various electronic devices and systems.
• Collaborated with cross-functional teams to ensure project alignment and integration.
• Conducted thorough testing of prototypes to validate design specifications and functionality.

• Led military simulation projects utilizing machined components, sheet metal, welding processes, and plastic materials to meet project specifications.
• Conducted consultations at client locations to identify client needs and improve project outcomes.
• Designed innovative mechanical systems for diverse applications in defense technology.
• Collaborated with cross-functional teams to enhance product development processes.
• Led design reviews to ensure compliance with industry standards and specifications.

• Designed 10 pt. patch for EKG testing and hand-held device for Stryker cardiac monitoring to enhance patient diagnostics.
• Designed mechanical systems for various defense and training applications.
• Collaborated with cross-functional teams to ensure project alignment and execution.
• Analyzed complex engineering problems to develop effective solutions and strategies.

• Collaborated with Japan-based design team on Rugged Monitors project, focusing on vibration performance.
• Conducted shake and vibe tests, addressed EMI issues, managed heat transfer, designed heat sinks, and implemented waterproof sealing for effective temperature range (85C to -20C).
• Resolved the ongoing monitor sealing problem by developing an effective solution on the first day.
• Achieved 30% cost reduction and 10% weight savings, implementing design changes to rear electronics cover across five product lines (19-24" sizes).
• Documented and highlighted key accomplishments to showcase project success.

• Transitioned to Engineering Manager role, leading initiative for ISO 9001-2015 certification.
• Directed engineering projects, managing job orders and supply chain to optimize workflow.
• Developed projects for machined and sheet metal parts, and electronic control panels.

• Updated CEO daily on progress of electronic enclosures, gear drives, optics, and EM controls.
• Led design efforts for new PCBs, power supplies, and optics lenses as Director of Engineering.
• Designed and inspected all parts post-manufacturing, reducing optical assembly time from 6 hours to 20 minutes through significant design change; managed production operations for local and San Diego offices.

• Designed military simulations using precision-machined and sheet metal parts, overseeing on-site installation during multiple multi-week trips.
• Accomplishments:
• Realigned C-17 Trainer Project, achieving deliverable status within 7 months while adhering to contract specifications.
• Replicated interior components, including floor mechanism, lighting, hydraulic ramp sections, cylinder hydraulic locks, and manual override lift/drop mechanism for floor panels.

Led mechanical and structural design of multi-million-dollar Gasification System Generation II at Sanford FL wastewater treatment plant, enabling biosolid burning to eliminate solid waste, reduce landfill use, and produce clean renewable energy to offset operational costs. Utilized SolidWorks Simulation for FEA stress and thermal analysis; designed E/M packaging, structural support with 3/8" rolled steel and I-beams, machined parts, ASME standard and custom flanges for pressure vessel, piping per ASME B31.3 standards, and stair and railing systems across 22,000 sq. ft. location.

Achieved 93% efficiency in the innovative Gasification System Generation II.

Designed thermal oxidizer sections with transition through custom cyclone and expansion joints, achieving $350,000 savings; ensured industrial piping conformance to AWS, ASME, and ASME B31.3 standards.

Established first part numbering system, drafting standards, drawing templates, document control system, and ECO/ECR process, filling significant gap in design documentation.

Accomplishments:

Served as sole engineer for mechanical designs, creating electronic housing enclosure assemblies, including card guides, ESOP, PCBs, connectors, waveguide parts/assemblies, wiring and harness connections, EM controls, heat transfer and cooling, PWB, CCA, and brass waveguides for COTM II satellite antenna system for vehicles.

Complete NPD of Electronic Enclosures both internal and exposed to weather (-40ºF to 180ºF). Additional designs consisted of Gear Drives, Hydraulics, Cable/Harness, Breakers, Shock & Vibe, precision-machined parts, Sensors, Composite materials & Sheet Metal parts.

Designed flagship SATCOM COTM antenna (Communication on the move) starting in 2005 and Gen II in 2008, completing redesign to meet cost reduction mandate while researching and implementing methods to replace machined and stamped sheet metal parts with composite materials.

Reduced shock mounts from $2400 to $60 per unit, achieving projected savings of $702,000 over first 2 years by cutting costs over 60% on materials and assembly time, reducing inventory by 20%, and decreasing weight by over 20%, leading to savings of $30,000 per unit and increased monthly unit output.

Major Accomplishments:

• Performed tolerance study analysis on military products, focusing on heavy GD&T machined parts to ensure precision and compliance with specifications.
• Inspected materials for quality and compliance with specifications.
• Verified documentation for accuracy and completeness before processing.
• Coordinated with production teams to ensure timely material flow.