Robert Michels

Engineering Design

• Key contributor in first article inspections of project delivered from offshore factories to validate if designs implemented per engineering specifications
• Prototype designs prior to new product development process for mechanical and electrical engineering teams of up to 14 engineers
• Prototype key designs for research and development to prove out conceptual designs for engineering team. Key contributor in modification of designs prior to prototyping to improve functionality and performance
• Key contributor to mechanical design brainstorming sessions and design reviews

Testing and Quality

• Data acquisition setup and placement of sensors, strain gages, and instrumentation setup for data collection
• Design and fabrication of static and life cycle test fixtures
• Design and fabrication of electronic systems development kits for electrical and firmware engineering testing
• High force material test system (MTS) setup; complete tests per engineering requirements
• Perform field testing and outfitting of vehicles with DAQ and sensors per engineering requirements
• Maintain and repair test equipment and machines in test lab
• Experience using touch probe and laser scanning CMM arm

Fabrication

• Skilled fabricator using a variety of steel, including stainless and aluminum alloys, fiberglass, Kevlar, carbon fiber, silicone parts from mold making to final part
• Metal and plastic fabrication: manual mill, lathe, band saw, sheer, sheet metal shaping, punching, CNC Plasma cutting, TorchMate
• Performed CNC 3-axis mill and lathe programming with CAMWorks
• Additive machining: point of contact for file setup, programming, running, maintenance, and lead for repair and maintenance of equipment
• Performed post machining of 3D printed prototypes, equipment included F370 FDM and Formlabs
• Welding: MIG, TIG and gas. Materials include steel, aluminum, and stainless steel. Created and set up custom fixtures for welding
• Painting: sandblasting, grinding, surface prep; use of HVLP and airless paint guns
• Electrical: work from engineering drawings to assemble, wire and test industrial control panels
• Work with rough sketches to wire and troubleshoot complete prototype wiring harnesses for multiple product applications, including fitness equipment and motor vehicles

Project Management and Leadership

• Mentor junior lab technicians, shop technicians and mechanical engineers
• Lead teams from 4 to 20 members, including small vehicle crew to interdisciplinary project teams
• Support customer care team in troubleshooting and root cause analysis of customer product issues
• Key contributor to engineering design reviews and risk analysis for new products. Effectively communicate fabrication capabilities required in engineering designs and improve for manufacturability, reducing design cost and complexity without reducing functionality
• Active leader in Safety Committee and cross-department Culture Committee, resulting in employee retention and improved morale across all departments
• Lead design and fabrication support for teams of 200 plus people, including marketing, engineering, sales, customer service/warranty, and customer contact care center
• Plan and purchase materials needed to maintain shop equipment, including sourcing repairs for all equipment
• Familiar with safety procedures and knowledge of personal protective equipment
• Pneumatics and Hydraulics