Sarah Brennan

Motivated, adaptable Materials and Process Engineer with over 12 years’ experience in materials processing, manufacturing, research and analysis with composites, light metals and alloys, heat treat, and corrosion protection schemes. I thrive in high pressure work environments, and have worked in and with Fortune 500, government, and military contractors and suppliers. I pride myself in being self-motivated, a quick learner, taking the lead and having excellent communication skills. Forward-thinking Process Engineer with more than [Number] years of experience in process design and establishing manufacturing routines. Known for great time management, effective multitasking and detail-oriented planning.

• Microsoft Office Suite including MS Project and SharePoint
• Minitab
• CMH17 STATS
• Trained in Six Sigma Methodology to Green Belt level
• VISUAL ERP
• NASA MAPTIS database
• Optical Microscopy
• Mechanical and quality assurance testing of metals and composites
• Secondary Electron Microscopy (SEM)

• Materials and Process Engineer III, Blue Origin, Kent, WA, 05/01/20, Present, Lead a technical team in the material change and resolution of forged material property issues and supply for Landing Gear System forgings to include a full qualification of material and suppliers, Leading efforts to standardize Hydrogen Peroxide compatibility assessment efforts across New Glenn Teams, Broad materials & processes support for metallic, non-metallic, and composite materials including: forgings, forming, extrusion, plating, coating, anodization, and passivation, solid and sandwich laminates., Support design, analysis, materials selection, process development, and M&P qualification for New Glenn Mechanical Systems, for GS1 and GS2., Review production drawing for parts and complex assemblies systematically, documenting the review to the established requirements, Responsible for M&P signatory release of engineering drawings for parts and assemblies, Lead and coordinate internal and external M&P efforts, including development of specifications, supplier qualification, First Article Inspection, mechanical testing, and customer-facing updates, Resolve Non-conformances both internally and externally as appropriately related to Materials and Process issues alongside Engineering and Quality, Work with cross-functional teams within the New Glenn organization and other business units.
• Sr. Materials Engineer, The Spaceship Company, Mojave, CA, 08/01/19, 03/01/20, Overhaul of in-house Chem Film line process for Aluminum alloys, including new proposal, new Process Specification, Process specification writing and editing/updating, Data analysis of material property test data for material allowables using CMH17 methods and software, CMH-17 STATS, Writing of test reports for internal distribution of material test data
• Sr. Materials Engineer, ATA Aerospace, LLC, Goddard, MD, 07/01/18, 01/01/19, Responsible for the verification, evaluation, control and application of materials and processes for aerospace systems and missions:, Supporting the development and execution of M&P selection, control, and implementation for in-house spacecraft and instruments for metallic and non-metallic materials, Identifying parts and processes requiring Materials Usage Agreements (MUA) in accordance with NASA-STD-6016 and approving MUA’s and MIUL’s (Materials Identification and Usage Lists), Providing technical expertise to project engineering including the selection and application of M&P, process development and qualification, Assisting project with milestone reviews, test reviews, and deviations related to materials and processes, Write technical memos, approve drawings, testing documents and specifications as the Materials and Process authority
• Engineering Project Manager, The Protective Group, Miami Lakes, FL, 10/01/17, 05/01/18, Engineering Project Manager for military platform armored components., Test plan development for new product design and qualification, Statistical test data analysis and report generation for internal and external customers, Project timeline/schedule development and tracking, Process capability analysis for spray coating manufacturing line
• Materials Certification Engineer, Superior Group, Hawthorne, CA, 04/01/17, 06/01/17, Materials certification and usage agreements for Falcon 9 rocket, crewed program, with NASA, Identifying parts and processes requiring a Materials Usage Agreement (MUA) per contract with NASA in accordance with NASA-STD-6016, Assisting Responsible Engineers with MUA identification and alterations to products and processes when applicable or desired., Development of tracking method for MUA submissions to NASA customers, approvals and feedback as well as technical discussions with relevant parties to address customer concerns and achieve program objectives
• Process Engineer for Composite Panels, Laminates and Aluminum Honeycomb, The Gill Corporation, El Monte, CA, 07/01/14, 04/01/17, Leading technical and analytical projects and efforts including:, Manufacturing process improvement to meet customer needs and company’s quality goals including reduction in costs, cycle times, improvements in tooling, process layouts, raw materials and technical documentation including operating procedures, Product and Process Cost reductions including major manufacturing aid material change resulting in over $230k savings annually, Capital project management for $300K+ of new tooling and implementation, Continuous improvement activities with the use of Six Sigma and Lean manufacturing skills and tools (Gage R&R, 5S, Process Mapping, PFEMA, etc.), Root Cause Corrective action investigations for production issues and customer concerns, MRB participation for product non-conformances, and SPC analysis of QA data, Supplier audits for determination of process and product qualifications and compliance to customer specifications, Writing, editing and maintaining internal process and material specifications, work instructions, test plans, Interface with Sales, R&D, and production to coordinate projects to satisfy customer needs
• Metallurgical Engineer (Materials, Processes & Technologies), Boeing Research & Technology, Vertical Lift, Mesa, AZ, 08/01/12, 04/01/14, Providing technical and analytical support to various projects as assigned including:, Qualification of new magnesium direct chill cast billet material and manufacturing process reducing product lead times by 7 months and eliminating tooling costs from using sand castings., Statistical analysis including calculation of AMS S-basis mechanical property values, writing new material specification for the direct chill cast billet, Engineering (M&P) lead for in-house aluminum heat treat facility:, Analyzing temperature uniformity survey data, mechanical property, hardness testing and electrical conductivity data to ensure material and equipment compliance with required specifications utilizing SPC charts and practices, Resolving temperature and/or soak time non-compliances with materials and parts, Assisting with operator training programs for material inspection techniques, Conduct supplier audits to Boeing material and process technology specifications and external (AMS, ASTM, MIL) specifications, Write and revise engineering specifications to support experimental and legacy aircraft initiatives, Material and manufacturing process qualification, first article inspections (FAI) and support for airframe and drive system components and manufacturing technologies to include aluminum and magnesium-based components.
• Materials Scientist/Engineer, Weapons and Materials Research Directorate, Army Research Laboratory, Aberdeen Proving Ground, MD, 08/01/11, 08/01/12, Providing technical and analytical support to various projects as assigned including:, Cryomilling (ball milling in liquid nitrogen) of aluminum-based alloys and metal matrix composites to produce/fabricate nanostructured materials via powder metallurgy methods, Materials characterization: particle size analysis, morphology, scanning electron microscopy, Laboratory operation and maintenance of cryomilling, degassing and glove box equipment, Data analysis of diffusion in magnesium-rare earth (Mg-RE) systems, Assist with proposal preparation and writing, writing of peer-reviewed journal articles and deliver technical presentations at internal and external technical conferences and seminars, Supplier, internal and external customer service and interfacing to coordinate projects and assets